INDEX
Copyright © ATSG 2008
UPDATE HANDBOOKJF506E
AUTOMATIC TRANSMISSION SERVICE GROUP18639 S.W. 107 AVENUEMIAMI, FLORIDA 33157
(305) 670-4161
BELL HOUSING IDENTIFICATION .....................................................................................................CUT-AWAY AND INTERNAL COMPONENT LOCATIONS .................................................................COMPONENT APPLICATION CHART AND GEAR RATIOS .............................................................RANGE SELECTOR SWITCH CONNECTOR IDENTIFICATION ......................................................OIL PAN IDENTIFICATION ...................................................................................................................ELECTRONIC COMPONENTS, TERMINAL IDENTIFICATION, WIRE SCHEMATICS ...............INTERNAL ELECTRONIC COMPONENT LOCATIONS AND DIAGNOSIS .....................................SOLENOID IDENTIFICATION AND LOCATIONS ..............................................................................DIAGNOSTIC TROUBLE CODE DESCRIPTIONS ...............................................................................VALVE BODY EXPLODED VIEWS AND CHECKBALL LOCATIONS ...............................................SPACER PLATE DIFFERENCES ...........................................................................................................VALVE BODY CASTING IDENTIFICATIONS ......................................................................................VALVE BODY TO CASE BOLT LOCATIONS ........................................................................................VALVE BODY ASSEMBLY PROCEDURE (FREELANDER) ...............................................................FLUID REQUIREMENTS FOR ALL MODELS ....................................................................................CHECKING FLUID AND FILLING PROCEDURES ............................................................................NO REVERSE AFTER REBUILD ...........................................................................................................LINE PRESSURE TAP IDENTIFICATION AND SPECIFICATIONS ................................................OIL PUMP ASSEMBLY INFORMATION AND SPECIFICATIONS ....................................................REDUCTION BAND ADJUSTMENT ......................................................................................................REDUCTION SERVO DIFFERENCES ..................................................................................................FLUID FILTER DIFFERENCES ............................................................................................................OIL PUMP GASKET WARNING .............................................................................................................INPUT SHAFT AND TRANSFER GEAR DIFFERENCES ..................................................................DIFFERENTIAL AND TRANSFER GEAR RATIO CHARTS BY MODEL .........................................FINAL DRIVE IDENTIFICATION .........................................................................................................2-3 FLARE OR SLIPS IN 3RD, 4TH AND 5TH ......................................................................................REPEATED LUBE FAILURE (VOLKSWAGEN ONLY) ........................................................................DIRECT CLUTCH DIFFERENCES ........................................................................................................CASE PASSAGE IDENTIFICATION ......................................................................................................END COVER AND 2-4 BRAKE CLUTCH PISTON DIFFERENCES ..................................................END COVER "V"-CUT SEALING RINGS .............................................................................................LOW ROLLER CLUTCH AND SNAP RING INFORMATION .............................................................LOW/REVERSE CLUTCH INSTALLATION INFORMATION .............................................................LOW CLUTCH "STEPPED" SEALING RINGS ....................................................................................DIRECT CLUTCH "STEPPED" SEALING RINGS ..............................................................................
3456
14153336424662656768848487889293949696979899
100102104107108109110110112112
INTRODUCTIONJATCO JF506E
"UPDATE HANDBOOK"
AUTOMATIC TRANSMISSION SERVICE GROUP18635 S.W. 107 AVENUEMIAMI, FLORIDA 33157
(305) 670-4161 1
No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form or by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise, without written permission of Automatic Transmission Service Group. This includes all text illustrations, tables and charts.
The information and part numbers contained in this booklet havebeen carefully compiled from industry sources known for their
reliability, but ATSG does not guarantee its accuracy.
Copyright © ATSG 2008
1st PrintingFebruary, 2008
DALE ENGLANDFIELD SERVICE CONSULTANT
ED KRUSETECHNICAL CONSULTANT
WAYNE COLONNAPRESIDENT
PETER LUBANTECHNICAL CONSULTANT
JIM DIALTECHNICAL CONSULTANT
GREGORY LIPNICKTECHNICAL CONSULTANT
JON GLATSTEINTECHNICAL CONSULTANT
DAVID CHALKERTECHNICAL CONSULTANT
ROLAND ALVAREZTECHNICAL CONSULTANT
GERALD CAMPBELLTECHNICAL CONSULTANT
FOUND IN: MANUFACTURERS I.D.JA5A-ELJA5A-ELJF506EJF506E
09A09A09A
Mazda "MPV" beginning in 2002 (3.0L V6) .......................................Mazda "6" beginning in 2003 (3.0L V6) ..............................................Land Rover "Freelander" beginning in 2002 (2.5L V6) ........................Jaguar "X" Type beginning in 2002 (2.5L/3.0L V6) ..............................VW "Jetta" beginning in 2002 (1.8L Gas/1.9L Diesel) ............................VW "GTI" beginning in 2002 (1.8L Engine) ............................................VW "Golf" beginning in 2004 (1.9L Diesel) ..............................................
As you can see from above, with different manufacturers comes different identifications. These transaxles are all similar in the teardown and assembly process, but the internal and external parts are different in the design and engineering area. This manual is designed to identify the engineering differences between the current models available at this time.
Phoenix RemanufacturedTransmissions
PHXRETRANS
A VERY HEARTY "THANK YOU" TO FRANK KUPERMAN OF
PHOENIX REMANUFACTURED TRANSMISSIONSFOR SUPPLYING US WITH THE TRANSMISSIONS THAT MADE
THE ILLUSTRATIONS IN THIS BOOKLET POSSIBLE.
1 (623) 936-1500PLEASE FEEL FREE TO CALL TODAY
Figure 1
3
Jaguar X Type Land RoverFreelander
Mazda "6"And "MPV"
VolkswagenGolf, GTI And Jetta
Copyright © 2008 ATSG
BELL HOUSING IDENTIFICATION INTERNAL COMPONENT LOCATION
BELL HOUSING IDENTIFICATION
The JF506E transaxle is manufactured in Japan by JATCO and is used in the USA in the Land Rover Freelander, Jaguar X Type, Mazda "6" and "MPV" and the Volkswagen Golf, GTI and Jetta. The JF506E transaxles can be identified very easily between the different users by the shape of the bell housings, as shown in Figure 1.
Internal component locations are shown in the cut-away in Figure 2 and the application chart is shown in Figure 4. Gear ratios vary between the car manufacturers as well as within the same user. There are also different final drive ratios so care must be used should replacement be necessary. We have provided you with a ratio chart in Figure 3.
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
4
LOW ROLLERCLUTCH
LOW/REVERSECLUTCHREVERSE
CLUTCH
HIGHCLUTCH
REDUCTIONSPRAG
REDUCTIONBAND
REDUCTIONBAND SERVO
DIRECTCLUTCH
LOWCLUTCH
2-4CLUTCH
MAZDA JF506E COMPONENT LOCATIONS
Copyright © 2008 ATSG
Figure 2
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
5
JF506E PLANETARY GEAR RATIOSLand RoverFreelander
2.5L V6
Land RoverFreelander
Turbo DieselMaxda 63.0L V6
1st Gear 3.801 3.801 3.801 3.8013.801 3.801 3.8013.474
2.131 2.131 2.131 2.1312.131 2.131 2.1311.948
1.364 1.364 1.364 1.3641.364 1.364 1.3641.247
0.935 0.935 0.935 0.9350.935 0.935 0.9350.854
0.685 0.685 0.685 0.6850.685 0.685 0.6850.685
2.970 2.970 2.970 2.9702.970 2.970 2.970
2.87Transaxle Code "EEB" = 3.45
Transaxle Code "EYN" = 3.45
Transaxle Code "EEF" = 2.70
3.23 3.04 3.23
2.714
3.04
2nd Gear
3rd Gear
4th Gear
5th Gear
Reverse
Differential Ratio
Maxda MPV3.0L V6
JaguarX Type
2.0L/2.5L/3.0L
VWGolf
1.9L Diesel
VWJetta
1.8L/2.8L
VWGTI1.8L
Mazda "6" Indicator Mazda "MPV" Indicator Freelander Indicator
Volkswagen IndicatorJaguar "X" Indicator
P R N D P R N D 3 2 P R N D 4 2 1
P R N D 4 3 2P R N D 4 3 2
Mazda MPVRANGE
JF506E COMPONENT APPLICATION CHART
Park/Neutral
Reverse
GEAR
R On
On On
On
On
On
On
On
On
On
On
On
On
On
On
On
On
On On
On
On
On
On
On
On
On
On
On
On
ReductionBand
On
Low/ReverseClutch
On
ReverseClutch
"D"
OD Cancel"OFF"
1st
2nd
3rd
4th
5th
ReductionSprag SSA SSB
Shift Solenoids
SSC
Hold
Hold
Hold
Hold
Hold
Hold
Hold
Hold
Hold
Hold
DirectClutch
On
"D"
OD Cancel"ON"
"3"
"2"
1st
1st
1st
2nd
2nd
2nd
3rd
3rd
4th
LowRollerClutch
Hold
Hold
Hold
Hold
2-4Clutch
On
On
On
On
On
On
On
LowClutch
On
On
On
On
On
On
On
On
On
On
On
HighClutch
On
On
On
On
On
On
COMPONENT APPLICATION CHARTS
Copyright © 2008 ATSG
Figure 3
Figure 4
Transaxle Range Selector Indicators vary in the number of range positions between vehicle users. There are 4, 6, and 7 position indicators. The example shown above is for the Mazda MPV, 6 position indicator.
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
Transaxle Range Selector Switch
The Mazda "6" will have four positions (P R N D), and has a nine pin electrical connector, as shown in Figure 5. Two of the pin and cavities are not used on the Mazda "6". The electrical connector is hard wired to, and part of, the Transaxle Range Selector Switch. Connector terminal identification is shown in Figure 7. The Mazda "6" shift quadrant is shown in Figure 10.
The Mazda "MPV" will have six detent positions (P-R-N-D-3-2), and also has a nine pin electrical connector, but is different than the Mazda "6", as shown in Figure 6. All of the pins and cavities are used on the Mazda "MPV". The electrical connector is hard wired to, and part of, the Transaxle Range Selector Switch. Connector terminal identification is shown in Figure 8. The Mazda "MPV" shift quadrant is shown in Figure 9.
RANGE SELECTOR SWITCH IDENTIFICATIONMAZDA "6"
MAZDA "MPV"
All models of the JF506E transaxle, regardless of the manufacturer, use an external mounted Range Selector Switch. They are all typical range selector switches, commonly referred to in the past as an Inhibitor Switch. The detent positions vary and may have four, six or seven positions, depending on model useage. We are covering 5 different versions of the JF506E transaxle in this manual, and there are five different range switch electrical connectors which we will identify for you, one at a time. This will make the diagnosis process much easier. Pay close attention to the wire schematics provided, as some models are equipped with a steptronic feature or a manual mode, that allows a "Slap-Stick" for Up and Down shift control, and some models are equipped with an overdrive cancel switch. Notice in the wire schematic charts that there is one terminal that is common for all ranges. This is the voltage supply terminal into the switch. When the ignition is in the "ON" position, there needs to be battery voltage at this terminal. If there is not, this needs to be repaired first. If voltage is present, it should exit the assigned terminal per range selected.
Copyright © 2008 ATSG
Transaxle RangeSwitch ConnectorNumber "A2-03"
MAZDA "6"P R N D
Transaxle RangeSelector Switch
Figure 6Figure 5
}
Transaxle RangeSwitch ConnectorNumber "A-03"
MAZDA "MPV"P R N D 3 2
Transaxle RangeSelector Switch
Copyright © 2008 ATSG
6 AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
7
Position/Range
PRND32
A-03 Connector Terminal
H B C A E D G I F
Transaxle Range SwitchVehicle Harness
Connector Number "A-03"Viewed From Terminal Side
H
IGECA
FDB
D
N
R
P
RangeSwitch
"A-03"Conn
TCM
TCM
IgnitionSwitch
FromBatteryMeter
Ign. 15A
From StarterRelay
3
2PCM (Term. 98)
H
A
E
D
G
I
F
B
2B
1W
1T
1Z
1AA
2C
C
OD OFF
Test Switch
Selector Lever
2I
1A
MAZDA "MPV"P R N D 3 2
Mazda 6 and MPV Range Selector Switch (Cont'd)
Copyright © 2008 ATSG
Figure 8Figure 7
starting purposes only. With the ignition switch "ON", there must battery voltage at terminal "C". If there is not, this must be repaired first. If voltage is present, it should exit the assigned terminal in each range selection.Notice also the Mazda "6" has a manual switch in the selector lever that allows manual shifting up and down (See Figure 10). The Mazda "MPV" is not equipped with the manual mode, but is equipped with an overdrive cancel button (See Figure 9).
Transaxle Range SwitchesContinued on next Page
A
BDFH
CEGI
Vehicle Harness ConnectorNumber "A2-03"
Viewed From Wire Side
Not Used
Position/Range
A2-03 Connector Terminal
H
PRND
B C A E D I F G
IgnitionSwitch
FromBatteryMeter
Ign. 15A
TCM
TCM
D
N
R
P
Not Used
Not Used
To PCMTerm. 98
StarterRelay
2B
1W
1T
1Z
P
R
N
D
Range Switch
"A2-03"Conn
A
E
D
I
F
G
B
C
H
Selector LeverM Range Switch
UP Switch
DN Switch1S
2C
1AA
MAZDA "6"P R N D
Copyright © 2008 ATSG
We have provided you with individual connector views, wire schematic and continuity chart for both the Mazda "6" and "MPV" in Figure 7 and 8. Although the charts in Figure 7 and 8 are used to check the integrity of the switch's range selection, using an Ohmmeter, the best method, is to check the range switch in the vehicle with a Volt meter. By looking at the charts in Figure 7 and 8, it can be seen that terminal "C" is the common terminal for all range selections. This is the voltage supply into the switch. Terminals "H" and "B" are used for
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
P
R
N
D
3
2
8
OD/OFFLIGHT
OD CANCELBUTTON
P R N D 3 2
OD/OFF
MAZDA "MPV" SHIFT QUADRANT
Copyright © 2008 ATSG
P
N
R
D M
+
MAZDA "6" SHIFT QUADRANT
Copyright © 2008 ATSG
VOLKSWAGEN SHIFT QUADRANT
Copyright © 2008 ATSG
P
N
R
D
4
3
2
Figure 9
Figure 10 Figure 11
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
Copyright © 2008 ATSG
View Looking IntoMulti-Function Switch
Connector
View Looking IntoMulti-Function Switch
Vehicle Harness Connector
In previous VW transaxles, mechanical circuits were used in the Multi-function switch. In this unit the mechanical circuits have been replaced by Hall senders. These non-contact switches are wear free. For inspection and repair, refer to the appropriate vehicle workshop manual.
1 3 5 77 5 3 1
86422468
VOLKSWAGENP R N D 4 3 2
Wv
JC7JP
NILES JAPAN
>PA66=GF33<
3E09
Copyright © 2008 ATSG
VolkswagenMulti Function Switch
Multi Function SwitchHarness Connector "T8"
VOLKSWAGENP R N D 4 3 2
RANGE SELECTOR SWITCH IDENTIFICATIONVolkswagen Range Selector Switch
Volkswagen refers to their range selector switch as a "Multi-Function" Switch, and it is illustrated in Figure 12. The multi-function switch detects the position of the selector lever and transmits this information to the Transaxle Control Module (TCM). The TCM then initiates the gear selections made by the operator. The TCM also activates the starter inhibitor relay, if the selector lever is placed in the "P" or "N" position. Notice also a "Tiptronic" feature is available that when selected, allows the driver to to upshift or downshift by moving the selector lever towards "+" or "-", as shown in Figure 11. In previous VW transaxles, mechanical circuits were used in the Multi-function switch. In this unit the mechanical circuits have been replaced by Hall senders. These non-contact switches are wear free. At present there is no "manual" test procedure available for this type of switch with Hall senders. The appropriate Volkswagen scanner must be used. For inspection and repair, refer to the appropriate vehicle workshop manual.
Figure 12
Figure 13
45
68
18
19
40
41
Fuse 21(30 Amp)
T68aConn
T8Conn
IgnitionSwitch
TCM
TCM
Multi-FunctionSwitch
5
7
2
4 3
6
Park/NeutralPosition
Relay
Brake Pressure Switch
Fuse 7(10A)
Exterior Lights
Exterior Lights
{
Start/ChargeSystem
Brake Switch
TiptronicSwitch
Shift Lock Solenoid
Fuse 13(10A)
54
60 37
61 42
2
62
8
17
21
24
1
5 8
1
1
6
3 5
19
2 6 8
7
4
9AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
Transaxle Range SwitchHarness ConnectorNumber "JB156"
TransaxleRange Switch
Copyright © 2008 ATSG
Copyright © 2008 ATSG
JAGUARP R N D 4 3 2
4
3
2
D
N
R
P
RANGE SELECTOR SWITCH IDENTIFICATIONJAGUAR "J-GATE" SHIFT QUADRANTJaguar Range Selector Switch
Figure 14
Figure 15
The Jaguar Range Selector Switch is shown in Figure 15. Notice there is not a manual shift lever on top like all the others, as the shaft goes all the way through the case and out the bottom, which is where the manual lever is located, and operated with a cable. Jaguar also uses a "J-Gate" system for the shift quadrant and it is shown in Figure 14. Jaguar uses two different types of Transaxle Control Module (TCM), a "16-bit" TCM and a "32-bit" TCM. In addition there is an "Early" style "16-bit" version, and a "Late" style "16-bit" version, that are different electronically. The early style 16-bit uses the J-gate with an overdrive cancel switch in the J-gate, and the range selector switch sends the signal for P, R, N, D, 3, 2. The late style does away with the overdrive cancel switch and includes 4, 3, and 2 in the wire harness from the J-gate to the TCM, while the range selector switch sends the signal for P, R, N, D. The 32-bit version was used in all models from mid 2003-up, and also does not have the overdrive cancel switch. We have provided you with individual connector views, wire schematics and continuity charts for all three versions, in Figure 16, 17, and 18, to check the integrity of the switch's range selection.
10 AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
(623) 936-15007310 W. Roosevelt #26Phoenix, AZ 85043
www. phoenixhardparts.com
Phoenix RemanufacturedTransmissions
PHXRETRANS
D-4 Switch on Shift Console
Position/Range
JB156 Connector Terminal
6 10 8 9 7 2 1 4 3 5
PRND234
2002 JAGUAR (EARLY) "16 BIT" TCMP R N D 4 3 2
Ignition Switch
TCM
TCM
D
2
3
4
N
R
PP
P
R
N
N
D
2
3
To ECMStart Circuit
Range Switch
J GateAssembly
23
PRND
MODE SWITCH
NOT IN PARKSWITCH CHECK
KEY-INWARNING
IGNITIONSWITCH
D-4 SWITCH
JB156Conn
JB131Conn
9
7
2
1
3
4
6
8
10
30
54
36
26
25
27
8
7
47
45
6
16
5
4
2IP14
Connector
Range
Range
JB156 Connector Terminals
IP14 Connector Terminals
6 10 8 9 7 2 1 4 3 5
2 14155
PRND
234
2002 JAGUAR (LATE) "16 BIT" TCMP R N D 4 3 2
Ignition Switch
TCM
TCM
D
234
N
R
PP
P
R
N
N
D
To ECMStart Circuit
Range Switch
J GateAssembly
2ND GEAR
3RD GEAR
4TH GEAR
234
PRND
MODE SWITCH
NOT IN PARKSWITCH
IP14Connector
9
7
2
1
6
8
10
30
54
36
26
25
27
47
45
6
5
157
148
4
2
CHECKKEY-IN
WARNING
IGNITIONSWITCH16
2
33
4
JB156Conn
JB131Conn
Figure 16 Figure 17
Copyright © 2008 ATSGCopyright © 2008 ATSG
View Looking IntoJB156 Connector
View Looking IntoJB156 Connector
1
6
5
10
1
6
5
10
11AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
Ignition SwitchTCM
TCM
D
234
N
R
PP
P
R
N
N
D
To ECMStart Circuit
Range Switch
J GateAssembly
2ND GEAR
3RD GEAR
4TH GEAR
234
PRND
MODE SWITCH
NOT IN PARKSWITCH
IP14Connector
9
7
2
1
6
8
10
18
19
10
35
36
34
41
43
6
5
1524
1427
4
2
CHECKKEY-IN
WARNING
IGNITIONSWITCH16
2
33
4
JB156Conn
JB230 (1-24)And
JB231 (25-45)Connectors
JB230 (1-24)And
JB231 (25-45)Connectors
Range
Range
JB156 Connector Terminals
IP14 Connector Terminals
6 10 8 9 7 2 1 4 3 5
2 14155
PRND
234
2004 JAGUAR "32 BIT" TCMP R N D 4 3 2
Figure 18
Copyright © 2008 ATSG
Copyright © 2008 ATSG
FREELANDER SHIFT QUADRANT
Figure 19
P
DS/M
4
12
NR
Copyright © 2008 ATSG
Transaxle Range SwitchHarness ConnectorNumber "CO244"
TransaxleRange Switch
Fill Plug
FREELANDERP R N D 4 2 1
Figure 20
View Looking IntoJB156 Connector
1
6
5
10
12 AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
Position/Range
CO244 Connector Terminal
6 10 8 9 7 2 1 4 3 5
PRND421
External TransaxleHarness Connector CO244
12
35
6 8
910
4
7
DD
NN
RR
PP
Sport/Manual(Steptronic)
Switch
TCM
TCM
4 4
2 2
1 1
CO244Conn
Ignition Switch
RangeSwitch
To ECMStart Circuit
StarterRelay
54
30 9
26 7
25 2
27 1
45 4
7 3
6
41 9 1
19 7
37 8 2
5
10 6
8
36MainRelay
FREELANDERP R N D 4 2 1
Copyright © 2008 ATSG
Figure 21
RANGE SELECTOR SWITCH IDENTIFICATIONFreelaander Range Selector Switch
The Range Selector Switch for the Freelander is located on the selector shaft on top of the transaxle and is connected to the main harness with a 10 pin connector, as shown in Figure 20. Notice there is no manual lever on top, as the selector shaft goes through the transaxle with the manual lever on the bottom and is operated with a cable. The selector lever position is displayed on the LED module in the center console, shown in Figure 19, and in the instrument cluster just left of the odometer and is determined by the selector lever position and range selector switch. The selector lever is attached to a gimbal mounting, which allows a selection of PRND421 in a forward and rearward direction and selection between automatic and sport/manual (S/M) mode in a left and right transverse direction, as shown in Figure 19. When the "D" position is selected, the TCM receives a signal that "D" is selected. When the selector lever is moved to the S/M position (to the right), and the TCM does not receive a signal from either the 4 or N sensors, it determines that sport mode has been selected. If the selector lever is not moved to the "+" or "-" positions, the TCM keeps the transaxle in sport mode for higher and harsher automatic shifts. If the TCM senses a signal from either the "+" or "-" sensor, it initates manual mode and selects the manual gear selection requested. Manual mode will be maintained until the TCM again senses a signal from the "D" sensor. We have provided you with individual connector views, wire schematic and continuity chart for the Freelander in Figure 21. Although the charts in Figure 21 are used to check the integrity of the switch's range selection, using an Ohmmeter, the best method, is to check the range switch in the vehicle with a Volt meter. By looking at the charts in Figure 21, it can be seen that terminal "8" is the common terminal for all range selections. This is the voltage supply into the switch. Terminals "6" and "10" are used for starting purposes only. With the ignition switch "ON", there must battery voltage at terminal "8". If there is not, this must be repaired first. If voltage is present, it should exit the assigned terminal in each range selection, as shown in the chart.
13AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
V W A GJP JC7
0 9 A 3 2 1 8 11
Figure 22
FPPM200MAZDA
0212132YO9743
MAZDA
0 STUDS 4 STUDS
2 STUDS3 STUDS
VOLKSWAGEN
FREELANDERJAGUAR
Fills Through Dipstick Tube By Final Drive Fill Plug
Fill Plug
Studs
Fill Plug
Each of the oil pans are also different, as shown in Figure 22. The Volkswagen, Jaguar, and Freelander all have studs on the oil pan, in different locations, for various shaped brackets for the individual applications. Notice also that those three have a fill
OIL PAN IDENTIFICATIONpipe and plug on the top of the pans, and the Volkswagen and Jaguar vent through the pan, where the others do not. The Mazda pan has zero studs and no fill plug on the pan, as it fills through the dipstick tube in the case, near the final drive. These pans will not interchange.
Vent
Vent
14
Copyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
ELECTRONIC COMPONENTSElectrical Connectors and Wire HarnessFor Mazda "6" And Mazda "MPV"
Figure 23 Figure 24
The JF506E transaxles all have a complex wire harness set-up, compared to previous units. On the Mazda units there are two external case connectors, as shown in Figure 23 and 24. One connector that provides voltage for all of the 9 solenoids, and one connector that provides a path for the three speed sensors and the TFT sensor. Both of these connectors merge into one harness, goes through a "Pass-thru" case connector, and once again splits into two more connectors internally. One connector with eight terminals for the three speed sensors and the TFT sensor, and one connector with ten terminals for the 9 solenoids and a ground. Refer to Figure 23 for the Mazda "6" version and Figure 24 for the Mazda "MPV" version. If any of these connectors are damaged, a complete wiring harness is required (See Figure 33). There is an internal wire harness that plugs into the 10-way internal connector and runs to each of the 9 solenoids and provides an internal ground. There is also an internal harness that plugs into the 8-way internal connector that provides a path for all
three speed sensors and the Transaxle Fluid Temp (TFT) sensor. Of course then there are connectors at each of the 9 solenoids, and more connectors at each of the 3 speed sensors and the TFT sensor. These internal harness' can also be seen in Figure 23 and 24. The internal harness' are the same on both the Mazda "6" and the Mazda "MPV". This makes the electronic diagnostic process a challenge, to say the very least, with a variety of connectors that may have corrosion or damage. We have provided you with individual terminal identification for the external and the internal connectors, and a resistance chart in Figure 25 for the Mazda "6", and Figure 26 for the "MPV". Terminal identification for the TCM is found in Figure 29, and is the same for both models. Wire schematics from transaxle to TCM are shown in Figure 27 for the Mazda "6" and Figure 28 for the Mazda "MPV".
15
Copyright © 2008 ATSG
}
}
TO SPEED SENSORSAND TEMP SENSOR
TO ALLSOLENOIDS
External TransaxleHarness ConnectorNumber "H2-06 "
Number"H2-04"
Number"H2-07"
External TransaxleHarness ConnectorNumber "H2-03"
Transaxle RangeSwitch ConnectorNumber "A2-03"
TransaxleRange Switch
MAZDA "6"
}
Copyright © 2008 ATSG
}
TO SPEED SENSORSAND TEMP SENSOR
TO ALLSOLENOIDS
External TransaxleHarness ConnectorNumber "H1-05"
Number"H1-03"
Number"H1-06"
External TransaxleHarness ConnectorNumber "H1-02"
Transaxle RangeSwitch ConnectorNumber "A-03"
TransaxleRange Switch
MAZDA "MPV"
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
16
86542
7
31
8 1 3 5
7 2 4 6
External TransaxleHarness ConnectorNumber "H2-06"
Internal TransaxleHarness "Male" Coupler
Connector Number "H2-07"
Internal TransaxleHarness "Female" CouplerConnector Number "H2-07"
7 & 8 = Temperature Sensor 5 & 6 = Output Shaft Speed Senor
1 & 2 = Turbine Shaft Speed Senor 3 & 4 = Intermediate Shaft Speed Sensor
(513 to 627 ohms) (513 to 627 ohms) (513 to 627 ohms) (Refer to Page 33)
External TransaxleHarness ConnectorNumber "H2-03"
17 14 13
15
11
10
9 16 18 12
1715
119
1618
1413
1012
1715
11910
1213141618
Internal TransaxleHarness "Male" Coupler
Connector Number "H2-04"
Internal TransaxleHarness "Female" CouplerConnector Number "H2-04"
9 & 14 = Shift Solenoid C9 & 13 = High Clutch Timing Solenoid
9 & 11 = TCC Solenoid 9 & 12 = 2/4 Brake Timing Solenoid
9 & 15 = Reduction Timing Solenoid 9 & 16 = Shift Solenoid B9 & 17 = Shift Solenoid A9 & 18 = Pressure Control Solenoid
9 & 10 = Neutral Shift Solenoid (14 to 18 ohms)(12 to 13.2 ohms)(2.6 to 3.2 ohms)(2.6 to 3.2 ohms)(14 to 18 ohms)(14 to 18 ohms)(14 to 18 ohms)(14 to 18 ohms)(2.6 to 3.2 ohms)
7
31
86542
2004 MAZDA "6" TRANSAXLE TERMINAL I.D. AND RESISTANCE CHART
Transaxle Range SwitchConnector Number "A2-03"(Terminal F and G Not Used)
Transaxle Range SwitchVehicle Harness (Wire Side)Connector Number "A2-03"(Terminal F and G Not Used)
CG AEI
DFH B
A
BDFH
CEGI
Copyright © 2008 ATSG
Figure 25
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
17
Copyright © 2008 ATSG
Figure 26
7 & 8 = Temperature Sensor 5 & 6 = Output Shaft Speed Senor
1 & 2 = Turbine Shaft Speed Senor 3 & 4 = Intermediate Shaft Speed Sensor
(513 to 627 ohms) (513 to 627 ohms) (513 to 627 ohms) (Refer to Page 33)
External TransaxleConnector Number "H1-05"
External TransaxleConnector Number "H1-02"
86542
7
31
Internal TransaxleHarness "Male" Coupler
Connector Number "H1-06"
Internal TransaxleHarness "Female" CouplerConnector Number "H1-06"
7
31
86542
1715
119
1618
1413
1012
Internal TransaxleHarness "Male" Coupler
Connector Number "H1-03"
Internal TransaxleHarness "Female" CouplerConnector Number "H1-03"
9 & 14 = Shift Solenoid C (14 to 18 ohms)9 & 13 = High Clutch Timing Solenoid (2.6 to 3.2 ohms)
9 & 11 = TCC Solenoid (12 to 13.2 ohms)9 & 12 = 2/4 Brake Timing Solenoid (2.6 to 3.2 ohms)
9 & 15 = Reduction Timing Solenoid (14 to 18 ohms)9 & 16 = Shift Solenoid B (14 to 18 ohms)9 & 17 = Shift Solenoid A (14 to 18 ohms)9 & 18 = Pressure Control Solenoid (2.6 to 3.2 ohms)
9 & 10 = Neutral Shift Solenoid (14 to 18 ohms)
1715
11910
1213141618
Transaxle Range SwitchConnector Number "A-03"
Transaxle Range SwitchVehicle Harness (Pin Side)Connector Number "A-03"
A
B D F H
C E G I
A
B D F H
C E G I
8135
7246
11 18 14 10 9 NotUsed
NotUsed12 13 15 16 17
2004 MAZDA "MPV" TRANSAXLE TERMINAL I.D. AND RESISTANCE CHART
CAUTION: Even though there are two blank terminals in the external transaxle connector "H1-02" as shown here, the mating connector from the TCM has two wires in these locations that are not used.
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
18
Copyright © 2008 ATSG
CAN "L"
CAN "H"
D
N
R
P
Selector Lever
Ignition SW
IgnitionKey1 (40A)
MeterIgn. (15A)
Not Used
Not Used
M Range Switch
UP Switch
DN Switch
Stop Lamp SW
PCM
Stop Lamps
TCM
TCM
TCM
TCM Located underleft side of dash
2/4 Brake Timing Solenoid
TCC Solenoid
SS C
SS B
SS A
Ground
Transaxle FluidTemp. Sensor
Automatic Transaxle
IntermediateSpeed Sensor
Turbine Speed Sensor
PC Solenoid
Output Speed Sensor
High Clutch Timing
Neutral Shift
Reduction Timing
H2-03Conn
H2-06Conn
Internal H2-04Connector
Internal H2-07Connector
1010
15 15
16 16
17 17
9 9
11 11
13 13
12 12
18
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
18
14 14
InternalVB Bolt
InternalVB Bolt
2D
2G
2T
2W
2P
2S
2U
2V
2Y
2X
1N
2F
1K
1X
1M
1V
1F
2M
1U
1S
2C
1AA
1B
2J
1Y
1C
Battery
To PCMTerm. 98
StarterRelay
2B
1P
2AA
2Z
1W
1T
1Z
P
R
N
D
Range Switch
A2-03Conn
A
E
D
I
F
G
B
C
H
Not Used
Position/Range
A2-03 Connector Terminal
H
PRND
B C A E D I F G
2004 Mazda "6" 3.0L EngineTRANSAXLE TO TCM WIRE SCHEMATIC
Use TCM Connector Terminal ID in Figure 29
On Page 20.
Figure 27
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
19
Copyright © 2008 ATSG
OD OFF
Test Switch
TCM Located underright front floor panel
D
2
3
N
R
P 2B
1W
1T
1Z
2C
P
R
N
D
2
3
A
E
D
G
I
F
C
CAN "L"
CAN "H"
Selector Lever
Ignition SW
IgnitionKey1 (40A)
MeterIgn. (15A)
Stop Lamp SW
PCMStop Lamps
TCM
TCM
TCM
2/4 Brake Timing Solenoid
TCC Solenoid
SS C
SS B
SS A
Ground
Transaxle FluidTemp. Sensor
Automatic Transaxle
IntermediateSpeed Sensor
Turbine Speed Sensor
PC Solenoid
Output Speed Sensor
High Clutch Timing
Neutral Shift
Reduction Timing
H1-02Conn
H1-05Conn
Internal H1-03Connector
Internal H1-06Connector
1010
15 15
16 16
17 17
9 9
11 11
13 13
12 12
18
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
18
14 14
InternalVB Bolt
InternalVB Bolt
2D
2G
2T
2W
2P
2S
2U
2V
2Y
2X
1N
2F
2K
1X
1M
1V
1F
2M
1U
2I
1A
1AA
1B
2J
1Y
1C
Battery
To PCMTerm. 98
StarterRelay
1P
2AA
2Z
Range Switch
A-03Conn
B H
Position/Range
PRND32
A-03 Connector Terminal
H B C A E D G I F
Use TCM Connector Terminal ID in Figure 29
On Page 20.
2004 Mazda "MPV" 3.0L EngineTRANSAXLE TO TCM WIRE SCHEMATIC
Figure 28
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
20
Copyright © 2008 ATSG
with eight terminals for the three speed sensors and the TFT sensor, and one connector with ten terminals for the 9 solenoids and a ground. Refer to Figure 30 for the internal connectors. If any of these connectors are damaged, a complete wiring harness is required (See Figure 33). There is an internal wire harness that plugs into the 10-way internal connector and runs to each of the 9 solenoids and provides an internal ground. There is also an internal harness that plugs into the 8-way internal connector that provides a path for all three speed sensors and the Transaxle Fluid Temp (TFT) sensor. Of course then there are connectors at each of the 9 solenoids, and more connectors at each of the 3 speed sensors and the TFT sensor. These internal harness' can be seen in Figure 30. The internal solenoid harness for the Volkswagen is unique to the VW and will not fit any other vehicle. This complex wiring system makes the electronic diagnostic process a challenge, to say the very least, with a variety of connectors that may have corrosion or damage. We have provided you with individual terminal identification for the external and the internal connectors, and a resistance chart in Figure 31 for the VW family. Terminal identification for the TCM is found in Figure 32, and is the same for all VW models. Wire schematic from transaxle to TCM is also shown in Figure 32, and is the same for all VW models.
Wv
JC7JP
NILES JAPAN
>PA66=GF33<
3E09
}
Copyright © 2008 ATSG
}
TO SPEED SENSORSAND TEMP SENSOR
TO ALLSOLENOIDS
ConnectorNo. "T10"
ConnectorNo. "T8"
External TransaxleHarness Connector
Number "T20b"
VolkswagenMulti Function Switch
VOLKSWAGEN
Electrical Connectors and Wire HarnessFor Volkswagen Golf, Jetta, GTI
Figure 30
Y V S P M J G D A
Z W T Q N K H E B
AA X U I F C
Y V S P M J G D A
Z W T Q N K H E B
AA X U I F C
2004 "Mazda 6" 3.0L And 2004 "Mazda MPV", 3.0L
Connector "One" Connector "Two"
TCM TERMINAL IDENTIFICATIONWIRE SIDE HARNESS CONNECTOR VIEW
Figure 29
The JF506E transaxles all have a complex wire harness set-up, compared to previous units. On the Volkswagen units there is one, 20 pin, ZF style, external case connector, as shown in Figure 30. These wires from the external case connector split into two more connectors internally. One connector
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
21
Copyright © 2008 ATSG
View Looking Into TheExternal TransaxleHarness Connector
Number "T20b"
18 & 11 = N92 Shift Solenoid C, (9 to 24 Ohms)18 & 12 = N90 Low Clutch Timing Solenoid , (9 to 24 Ohms)18 & 13 = N283 2-4 Brake Solenoid , (9 to 24 Ohms)18 & 14 = N281 Reduction Timing Solenoid , (9 to 24 Ohms)18 & 15 = N93 Pressure Control Solenoid , (1 to 5 Ohms)18 & 16 = N282 2-4 Brake Timing Solenoid , (1 to 5 Ohms)18 & 17 = N91 TCC Solenoid , (9 to 24 Ohms)
18 & 10 = N89 Shift Solenoid B, (9 to 24 Ohms)18 & 9 = N88 Shift Solenoid A, (9 to 24 Ohms)
1715
119 10
1213141618
View Looking Into TheInternal Transaxle
Harness "Male" CouplerConnector Number "T10"
View Looking Into TheMulti-Function Switch
Connector
View Looking Into TheMulti-Function Switch
Harness Connector "MS8"
View Looking Into TheInternal Transaxle
Harness "Male" CouplerConnector Number "T8"
View Looking Into TheInternal Transaxle
Harness "Female" CouplerConnector Number "T10"
View Looking Into TheInternal Transaxle
Harness "Female" CouplerConnector Number "T8"
1715
119
1618
1413
1012
123
45
6789
101112
1314
1516
17181920
86542
7
31
7 & 8 = G93 Transaxle Fluid Temp Sensor, (Refer to Page 33)5 & 6 = G68 Output Shaft Speed Senor, (400 to 600 Ohms)
1 & 2 = G182 Turbine Shaft Speed Senor, (400 to 600 Ohms)3 & 4 = G265 Intermediate Shaft Speed Sensor, (400 to 600 Ohms)
7
31
86542
VOLKSWAGEN TRANSAXLE TERMINAL I.D. AND RESISTANCE CHART
1 3 5 7
8642
357
8 6 4 2
Numbers are stamped into connector on the wire side.
Figure 31
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
22
Copyright © 2008 ATSG
TCM HarnessConnector T68a
Fuse 15(5A)
Fuse 21(30A)
TCM Located inthe passenger
(Right) side Firewall
2002 Volkswagen "GTI", "Golf", "Jetta"TRANSAXLE TO TCM WIRE SCHEMATIC
"N283" 2-4 Brake Solenoid
"N91" TCC Solenoid
"N92" Shift Solenoid C
"N89" Shift Solenoid B
"N88" Shift Solenoid A
Transaxle FluidTemp. Sensor
Automatic Transaxle
IntermediateSpeed Sensor
Turbine Speed Sensor
"N93" Pressure Control Solenoid
Output Speed Sensor
Battery
Ignition Switch
TCM
TCM
TCM
"N90" Low Clutch Timing Solenoid
"N282" 2-4 Brake Timing Solenoid
"N281" Reduction Timing Solenoid
T20bConn
Internal T10Connector
Internal T8Connector
T68aConn
T68aConn
226699
10 10 65
12 12 51
16 16 26
14 14 46
13 13 25
17 17 50
15 15 48
18
1 1 10
2 2 9
3 3 28
4 4 29
5 5 36
6 6 35
7 7 33
8 8 34
18 64
11 11 49
68
45
InternalVB Bolt
InternalVB Bolt
Park/NuetralPositionRelay
Brake Pressure Switch
Multi-FunctionSwitch
Fuse 7(10A)
Exterior Lights
Exterior Lights{Start/Charge
System
Brake Switch
TiptronicSwitch
Shift Lock Solenoid
Fuse 13(10A)
18 5
19 7
40 2
41 4 3
6
54
60 37
61 42
2
62
8
17
21
24
1
5 8
1
1
6
3 5
19
2 6 8
7
4
T8Conn
123
45
68
24
46
Figure 32
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
23
Copyright © 2008 ATSG
MAZDA "6" MAZDA "MPV"
VOLKSWAGEN
JAGUAR FREELANDER
Figure 33
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
24
Copyright © 2008 ATSG
These internal harness' can be seen in Figure 34. The internal solenoid harness for the Jaguar is unique to the Jaguar and will not fit any other vehicles. This complex wiring system makes the electronic diagnostic process a challenge, to say the very least, with a variety of connectors that may have corrosion or damage. We have provided you with individual terminal identification for the external and the internal connectors, and a resistance chart in Figure 35 for the Jaguar family. The Jaguar uses two different types of Transaxle Control Module (TCM), a "16-bit" TCM and a "32-bit" TCM. In addition there is an "Early" style "16-bit" version, and a "Late" style "16-bit" version, that are different electronically. The early style 16-bit uses the J-gate with and overdrive cancel switch in the J-gate, and the range selector switch sends the signal for P, R, N, D, 3, 2. The late style does away with the overdrive cancel switch and includes 4, 3, and 2 in the wire harness from the J-gate to the TCM, while the range selector switch sends the signal for P, R, N, D. The 32-bit version was used in all models from mid 2003-up, and also does not have the overdrive cancel switch. TCM connector identification is shown in Figure 39, for both the "16-bit" and "32-bit" versions. We have provided you with TCM to transaxle wire schematics for all three versions in the Jaguar family, in Figures 36, 37, and 38.
Electrical Connectors and Wire HarnessFor Jaguar "X" Type
The JF506E transaxles all have a complex wire harness set-up, compared to previous units. On the Jaguar units there is one, 18 pin, external case connector, as shown in Figure 34. These wires from the external case connector go through a "Pass-thru" case connector and then split into two more connectors internally. One connector with eight terminals for the three speed sensors and the TFT sensor, and one connector with ten terminals for the 9 solenoids and a ground. See Figure 34 for the Jaguar "X" Type version. If any of these connectors are damaged, a complete wiring harness is required (See Figure 33). There is an internal wire harness that plugs into the 10-way internal connector and runs to each of the 9 solenoids and provides an internal ground. There is also an internal harness that plugs into the 8-way internal connector that provides a path for all three speed sensors and the Transaxle Fluid Temp (TFT) sensor. Of course then there are connectors at each of the 9 solenoids, and more connectors at each of the 3 speed sensors and the TFT sensor.
External TransaxleHarness ConnectorNumber "JB155"
Transaxle Range SwitchHarness ConnectorNumber "JB156"
TransaxleRange Switch
Copyright © 2008 ATSG
}
}
TO SPEED SENSORSAND TEMP SENSOR
TO ALLSOLENOIDS
Number"JB10"
Number"JB8"
JAGUAR
Figure 34
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
25
Copyright © 2008 ATSG
1810
91 7 & 8 = Temperature Sensor 5 & 6 = Output Shaft Speed Senor
1 & 2 = Turbine Shaft Speed Senor 3 & 4 = Intermediate Shaft Speed Sensor
(513 to 627 ohms) (513 to 627 ohms) (513 to 627 ohms) (Refer to page 33)
18 & 13 = 2/4 Timing Solenoid18 & 12 = Low Clutch Timing Solenoid
18 & 10 = Shift Solenoid B 18 & 11 = Shift Solenoid C
18 & 14 = Reduction Timing Solenoid 18 & 15 = Pressure Control Solenoid 18 & 16 = 2/4 Duty Solenoid18 & 17 = TCC Solenoid
18 & 9 = Shift Solenoid A (14 to 18 ohms)(14 to 18 ohms)(14 to 18 ohms)(14 to 18 ohms)(14 to 18 ohms)(14 to 18 ohms)(2.6 to 3.2 ohms)(2.6 to 3.2 ohms)(12 to 13.2 ohms)
86542
7
31
Internal Transmission Harness "Male" CouplerConnector Number "JB8"
Internal Transmission Harness "Female" CouplerConnector Number "JB8a"
7
31
86542
1715
119
1618
1413
1012
Internal Transmission Harness "Male" CouplerConnector Number "JB10"
Internal Transmission Harness "Female" CouplerConnector Number "JB10a"
1715
11910
1213141618
View Looking Into TheJaguar X Type TransaxleHarness Connector JB155
(Face Side)
JAGUAR X TYPE TRANSAXLE TERMINAL I.D. AND RESISTANCE CHART
1
6
5
10
>PPA+PE<
5
10
1
6
View Looking Into TransaxleRange Sensor Connector JB156
View Looking Into VehicleHarness Connector JB156
Figure 35
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
2/4 Duty Cycle
TCC Solenoid
SS C
SS B
SS A
Transaxle FluidTemp. Sensor
Automatic Transaxle
IntermediateSpeed Sensor
Turbine Speed Sensor
PC Solenoid
Output Speed Sensor
Battery
Ignition Switch
TCM
TCM
TCM
Low Clutch Timing
2/4 Timing
Reduction Timing
D
2
3
4
N
R
PP
P
R
N
N
D
2
3
To ECMStart Circuit
}CAN
Range Switch
J GateAssembly
23
PRND
MODE SWITCH
NOT IN PARKSWITCH CHECK
KEY-INWARNING
IGNITIONSWITCH
D-4 SWITCH
JB155Conn
JB156Conn
Internal JB10Connector
Internal JB8Connector
JB131Conn
JB131Conn
TCM Located behindLeft Kick Panel
6
9
7
2
1
3
4
6
1599
10 10 14
12 12 53
13 13 4
14 14 10
16 16 3
17 17 16
15 15 18
18
1 1 44
2 2 24
3 3 46
4 4 21
5 5 42
6 6 5
7 7 39
8 8 20
18 17
11 11 52
8
10
30
54
36
26
25
27
8
7
47
45
33
34
9
38
6
16
5
4
2
IP14Connector
InternalVB Bolt
InternalVB Bolt
D-4 Switch on Shift Console
Position/Range
Connector Terminal
6 10 8 9 7 2 1 4 3 5
PRND234
Ground
2002 (Early Style) Jaguar X Type "16 Bit" TCMTRANSAXLE TO TCM WIRE SCHEMATIC
Use TCM Connector Terminal ID in Figure 39
26
Copyright © 2008 ATSG
Figure 36
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
2/4 Duty Cycle
TCC Solenoid
SS C
SS B
SS A
Transaxle FluidTemp. Sensor
Automatic Transaxle
IntermediateSpeed Sensor
Turbine Speed Sensor
PC Solenoid
Ground
Output Speed Sensor
Battery
Ignition Switch
TCM
TCM
TCM
Low Clutch Timing
2/4 Timing
Reduction Timing
D
234
N
R
PP
P
R
N
N
D
To ECMStart Circuit
}CAN
Range Switch
J GateAssembly
2ND GEAR
3RD GEAR
4TH GEAR
234
PRND
MODE SWITCH
NOT IN PARKSWITCH
JB155Conn
Internal JB10Connector
Internal JB8Connector
JB131Conn
JB131Conn
IP14Connector
TCM Located behindLeft Kick Panel
6
9
7
2
1
6
1599
10 10 14
12 12 53
13 13 4
14 14 10
16 16 3
17 17 16
15 15 18
18
1 1 44
2 2 24
3 3 46
4 4 21
5 5 42
6 6 5
7 7 39
8 8 20
18 17
11 11 52
8
10
30
54
36
26
25
27
47
45
33
34
9
38
6
5
157
148
4
2
CHECKKEY-IN
WARNING
IGNITIONSWITCH16
InternalVB Bolt
InternalVB Bolt
2
33
4
JB156Conn
Range
Range
JB156 Connector Terminals
IP14 Connector Terminals
6 10 8 9 7 2 1 4 3 5
2 14155
PRND
234
2002 (Late Style) Jaguar X Type "16 Bit" TCMTRANSAXLE TO TCM WIRE SCHEMATIC
Use TCM Connector Terminal ID in Figure 39
27
Copyright © 2008 ATSG
Figure 37
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
2004 Jaguar X Type "32 Bit" TCMTRANSAXLE TO TCM WIRE SCHEMATIC
Use TCM Connector Terminal ID in Figure 39
2/4 Duty Cycle
TCC Solenoid
SS C
SS B
SS A
Transaxle FluidTemp. Sensor
Automatic Transaxle
IntermediateSpeed Sensor
Turbine Speed Sensor
PC Solenoid
Output Speed Sensor
Battery
Ignition Switch
TCM
TCM
TCM
Low Clutch Timing
2/4 Timing
Reduction Timing
D
234
N
R
PP
P
R
N
N
D
To ECMStart Circuit
}CAN
Range Switch
J GateAssembly
2ND GEAR
3RD GEAR
4TH GEAR
234
PRND
MODE SWITCH
NOT IN PARKSWITCH
Internal JB10Connector
JB155Conn
Internal JB8Connector
InternalVB Bolt
InternalVB Bolt
JB230 (1-24)And
JB231 (25-45)Connectors
JB230 (1-24)And
JB231 (25-45)Connectors
JB230 (1-24)And
JB231 (25-45)Connectors
IP14Connector
TCM Located behindLeft Kick Panel
28
9
7
2
1
6
1199
10 10 12
12 12 8
13 13 21
14 14 7
16 16 2
17 17 3
15 15 1
18
1 1 44
2 2 24
3 3 46
4 4 21
5 5 42
6 6 5
7 7 39
8 8 20
18 4
11 11 20
8
10
18
19
10
35
36
34
41
43
14
15
25
48
6
5
1524
1427
4
2
CHECKKEY-IN
WARNING
IGNITIONSWITCH16
2
33
4
JB156Conn
Range
Range
JB156 Connector Terminals
IP14 Connector Terminals
6 10 8 9 7 2 1 4 3 5
2 14155
PRND
234
Ground
28
Copyright © 2008 ATSG
Figure 38
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
JB131Blue Connector
118
36 19
3754
JB230 (1-24)White Connector
JB231 (25-48)Grey Connector
1 9
10 18
19 24
25 3334 4243 48
Comprehensive Component Monitor Transmission Drive Cycle The Comprehensive Component Monitor Transmission Drive Cycle will “Check” all transmission components. 1. Engine and transmission at normal operating temperature. Ignition OFF; ensure that SPORT mode is NOT selected. 2. With gear select in P and the ignition ON. Check gearshift interlock by attempting to move the selector without pressing the brake pedal. Verify P state illumination. 3. Press and hold the brake pedal. Move the gear select to R. Verify R state illumination. 4. Set the parking brake. Press and hold the brake pedal. Attempt o start the engine. The engine should not start. 5. Move the gear select to N. Verify N state illumination. Start the engine. 6. With the hand brake set and the brake pedal pressed, move the gear select to the remaining positions in the J gate (D, 4, 3, 2) for five seconds. Verify the state illumination in each position. 7. Move the gear select switch back to 4. Verify 4 state illumination. 8. Move the gear select switch back to D. Verify D state illumination. 9. Move the gear select switch back to N. Verify N state illumination.10. Select R, release the brake and drive the vehicle in reverse for a short distance and stop the vehicle.11. Select 2 and drive the vehicle up to 40 mph (65 km/h) and hold for a minimum of 5 seconds.12. Select 3 and hold 40 mph (65 km/h) for a minimum of 5 seconds.13. Select 4 and hold 40 mph (65 km/h) for a minimum of 5 seconds.14. Select D and accelerate to a minimum speed of 50 mph (80 km/h). Hold 50-80 mph (80-129 km/h) for a minimum of 1 mile (1.7 Kilometers).15. Stop the vehicle; do NOT shut OFF the engine. Check for diagnostic codes.
2004 JAGUAR "X" TYPE"32-BIT" TCM
2004 JAGUAR "X" TYPE"16-BIT" TCM
29
Copyright © 2008 ATSG
Figure 39
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
30
Copyright © 2008 ATSG
}
Copyright © 2008 ATSG Copyright © 2008 ATSG
External TransaxleHarness ConnectorNumber "CO243"
Transaxle Range SwitchHarness ConnectorNumber "CO244"
TransaxleRange Switch
}
TO SPEED SENSORSAND TEMP SENSOR
TO ALLSOLENOIDS
Number"CO10"
Number"CO8"
FREELANDER
Figure 40 Figure 41
These internal harness' can be seen in Figure 40. The internal solenoid harness for the Freelander is unique to the Freelander and will not fit any other vehicle. Figure 41 illustrates an example of the internal solenoid harness. Example shown is for Mazda, but the others are similar. This complex wiring system makes the electronic diagnostic process a challenge, to say the very least, with a variety of connectors that may have corrosion or damage. We have provided you with individual terminal identification for the external and the internal connectors, and a resistance chart in Figure 42 for the Freelander. Terminal identification for the TCM is found in Figure 43, along with a TCM to transaxle wiring schematic for the Freelander.
Electrical Connectors and Wire HarnessFor Land Rover Freelander
The JF506E transaxles all have a complex wire harness set-up, compared to previous units. On the Freelander units there is one, 18 pin, ZF style external case connector, as shown in Figure 40. These wires from the external case connector go through a "Pass-thru" case connector and then split into two more connectors internally. One connector with eight terminals for the three speed sensors and the TFT sensor, and one connector with ten terminals for the 9 solenoids and a ground. See Figure 40 for the Freelander version. If any of these connectors are damaged, a complete wiring harness is required (See Figure 33). There is an internal wire harness that plugs into the 10-way internal connector and runs to each of the 9 solenoids and provides an internal ground. There is also an internal harness that plugs into the 8-way internal connector that provides a path for all three speed sensors and the Transaxle Fluid Temp (TFT) sensor. Of course then there are connectors at each of the 9 solenoids, and more connectors at each of the 3 speed sensors and the TFT sensor.
Example Of Internal SolenoidWiring Harness
ELECTRONIC COMPONENTSContinued on Page 33
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
31
Copyright © 2008 ATSG
7 & 8 = Temperature Sensor 5 & 6 = Output Shaft Speed Senor
1 & 2 = Turbine Shaft Speed Senor 3 & 4 = Intermediate Shaft Speed Sensor
(513 to 627 ohms) (513 to 627 ohms) (513 to 627 ohms) (Refer to page 33)
18 & 13 = 2/4 Timing Solenoid18 & 12 = Low Clutch Timing Solenoid
18 & 10 = Shift Solenoid B 18 & 11 = Shift Solenoid C
18 & 14 = Reduction Timing Solenoid 18 & 15 = Pressure Control Solenoid 18 & 16 = 2/4 Duty Solenoid18 & 17 = TCC Solenoid
18 & 9 = Shift Solenoid A (14 to 18 ohms)(14 to 18 ohms)(14 to 18 ohms)(14 to 18 ohms)(14 to 18 ohms)(14 to 18 ohms)(2.6 to 3.2 ohms)(2.6 to 3.2 ohms)(12 to 13.2 ohms)
Position/Range
Connector Terminal
6 10 8 9 7 2 1 4 3 5
PRND421
Figure 42
86542
7
31
Internal TransaxleHarness "Male" Coupler
Connector Number "CO8"
Internal TransaxleHarness "Female" CouplerConnector Number "CO8"
7
31
86542
1715
119
1618
1413
1012
Internal TransaxleHarness "Male" Coupler
Connector Number "CO10"
Internal TransaxleHarness "Female" CouplerConnector Number "CO10"
1715
11910
1213141618
2004 LAND ROVER FREELANDER TRANSAXLE TERMINAL I.D. AND RESISTANCE CHART
321
4 5 6 7
8 9 10 11
12 13 14 15
16 17 18
12
35
6 8
910
4
7
View Looking Into TransaxleRange Sensor Connector CO244
View Looking Into TransaxleHarness Connector CO243
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
32
Copyright © 2008 ATSG
Figure 43
2004 Freelander 2.5L EngineTRANSAXLE TO TCM WIRE SCHEMATIC
DD
NN
RR
PP
SteptronicSwitch
TCM
TCM
TCM
4 4
2 2
1 1
}
}
ECM
ABS
Brake Sensor
Cruise Control
Shift Interlock
TCM (ECU) Located in theUnder the Hood Electrical Center
2/4 Duty Cycle
TCC Solenoid
SS C
SS B
SS A
Transaxle FluidTemp. Sensor
Automatic Transaxle
IntermediateSpeed Sensor
Turbine Speed Sensor
PC Solenoid
Ground
Output Speed Sensor
Low Clutch Timing
2/4 Timing
Reduction Timing
CO243Conn
CO244Conn
Internal CO10Connector
Internal CO8Connector
CO932Conn
CO932Conn
1599
10 10 14
12 12 53
13 13 4
14 14 10
16 16 3
17 17 16
15 15 18
18
1 1
2 2 24
3 3
4 4 21
5 5
6 6 5
7 7 39
8 8 20
18 17
11 11 52
InternalVB Bolt
InternalVB Bolt
Battery
Ignition Switch
RangeSwitch
To ECMStart Circuit
StarterRelay
54
30 9
26 7
25 2
27 1
45 4
7 3
6
41 9 1
19 7
37
33
34
12
13
43
49
50
9
38
8 2
5
10 6
8
36MainRelay
Position/Range
CO244 Connector Terminal
6 10 8 9 7 2 1 4 3 5
PRND421
11937
183654
TCM HarnessConnector CO932
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
33
Copyright © 2008 ATSG
Copyright © 2008 ATSG
-20 {-4} 0 {32} 20 {68} 40 {104} 60 {140} 80 {176}100 {212}120 {248}130 {266}
15.87-17.54 5.73-6.33 2.38-2.63 1.10-1.22 0.56-0.62 0.31-0.34 0.18-0.20 0.11-0.12 0.09-0.10
Figure 45
Figure 44
ELECTRONIC COMPONENTS (CONT'D)Transaxle Fluid Temperature (TFT) Sensor
The Transaxle Fluid Temp (TFT) Sensor is located inside of the transaxle case housing, as shown in Figure 45, and requires disassembly if replacement becomes necessary. Resistance of the TFT sensor decreases as the fluid temperature increases, as shown in the chart in Figure 44. Input from the TFT is used by the TCM for converter clutch apply, torque reduction and fifth gear operation. To promote engine warm up during cold weather operation, the TCM may inhibit TCC apply until transaxle fluid temperature has reached approximately 104°F (40°C). Fifth gear may also be prohibited during cold weather operation, or when the TFT malfunctions. Torque reduction may also be inhibited when the TFT malfunctions. Use the charts for terminal identification specific to the vehicle you are working on, to check the TFT sensor, and the resistance chart in Figure 44 to verify proper reading. The TFT sensor may produce a Diagnostic Trouble Code (DTC) and the DTC numbers vary between the manufacturers. Check the vehicle specific DTC number and description in the DTC list in this manual.
TFT Sensor
TRANSAXLE FLUID TEMPERATURE (TFT) SENSOR
ATF TemperatureC° {F°}
Resistance(kilohm)
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
Figure 46
Figure 47
ELECTRONIC COMPONENTS (CONT'D)SPEED SENSORS There are three inductive type speed sensors located inside of the transaxle case housing and are not accessible from outside. Disassembly is required, if replacement becomes necessary. The Turbine Shaft Speed sensor is the only one that can be accessed in the vehicle, by removing the rear cover, as shown in Figure 47. The other two speed sensors require transaxle removal, and splitting the case. The speed sensors are, Turbine Shaft Speed Sensor, Intermediate Shaft Speed Sensor and the Output Shaft Speed Sensor. Electrical connections to all of the speed sensors and TFT sensor come through the external connector and the 8-way internal connector to reach these components. All three speed sensors are the same, but different brackets are used to mount them in their proper locations. Amazingly Mazda, Jaguar, and Freelander are all using the same speed sensor. All 3 speed sensors should measure the same resistance at 68°F (20°C), as shown in Figure 46, and can also be checked through the appropriate terminals on the external case connector.
05.75
OFF
RPM
RPMCOMmAA
10A MaxFUSED
V
V
mVW
W
W
VmAA
mAA
DCAUTO
FLUKE 88
k
Copyright © 2008 ATSG
TurbineShaft Speed
Sensor
All Three Speed Sensors Should Measure As Follows:
Mazda, Jaguar, Freelander = 513-627 Ohms
Volkswagen = 400-600 Ohms
Volkswagen Part Number = 09A 927 321
Mazda Part Number = FP21-21-2550
Continued on Page 35
34
Copyright © 2008 ATSG
TURBINE SHAFT SPEED SENSOR
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
SPEED SENSORS (CONT'D) Intermediate Shaft Speed Sensor
Output Shaft Speed Sensor
The Intermediate Shaft Speed sensor is positioned, as shown in Figure 48, to read the transfer "Drive" gear, which is driven by the 1st and 2nd planetary gearset. The sensor detects a pulse signal according to the teeth on the transfer drive gear. Since there are various ratios, the tooth count will vary. The input of the intermediate shaft speed sensor is used by the TCM to calculate the timing of engagements and disengagements of the brake clutches, and to monitor gear ratio. This sensor may produce a Diagnostic Trouble Code (DTC), but the code numbers vary between manufacturers. Check the DTC list in this manual for code numbers and description.
The Output Shaft Speed sensor is positioned, as shown in Figure 48, to read the "Park Gear", which is driven by the output shaft. The sensor detects a pulse signal according to the teeth on the park gear. The input of the output shaft speed sensor is used by the TCM to provide a vehicle speed signal, calulate shift timing, line pressure control, and to monitor gear ratio. This sensor may produce a Diagnostic Trouble Code (DTC), but the code numbers vary between manufacturers. Check the DTC list in this manual for code numbers and description.
IntermediateShaft Speed
Sensor
OutputShaft Speed
Sensor
35
Copyright © 2008 ATSG
Figure 48
INTERMEDIATE SHAFT AND OUTPUT SHAFT SPEED SENSORS
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
Turbine Shaft Speed Sensor
The Turbine Shaft Speed sensor is positioned, as shown in Figure 47, to read the high/reverse clutch housing which is splined to the turbine shaft. The TSS sensor detects a pulse signal from the projections on the outside of the high/reverse clutch housing. The speed sensors can be checked externally, as shown in Figure 46. The Turbine Shaft Speed sensor is the only one that can be accessed in the vehicle, by removing the rear cover, as shown in Figure 47. The information from the TSS sensor is used by the TCM to monitor gear ratio, line pressure control and to monitor and control TCC apply. This sensor may produce a Diagnostic Trouble Code (DTC), but the code numbers vary between manufacturers. Check the DTC list in this manual for code numbers and description.
36
Copyright © 2008 ATSG
SOLENOID IDENTIFICATION AND LOCATIONS
There are a total of nine (9) solenoids used on all models, which can be classified as two different types, because of the way in which they operate. Three of them are duty cycle solenoids, the other six are On/Off solenoids. Solenoid names and functions are different between the manufacturers. All solenoids in all models are actuated (energized) by a voltage feed from the TCM.
The Mazda solenoid locations and names are identified for you in Figure 49, and are the same for both Mazda "6" and Mazda "MPV". The shift solenoid firing sequence is the same on all models, and is also shown in Figure 49.
23PM-SUB
F
JC7 JP
B021204N
-1
K
1 2 3 4
5
6
8
9
Manual Valve
7
Mazda Solenoid Identification And LocationManufacturer
Mazda "6"And
Mazda "MPV"
1 2 3 4 5 6 7 8 9Reduction
TimingSolenoid
ShiftSolenoid
"C"
ShiftSolenoid
"B"
ShiftSolenoid
"A"
2/4 BrakeTiming
Solenoid
NeutralShift
Solenoid
High ClutchTiming
Solenoid
TCCSolenoid
LinePressureSolenoid
Shift Solenoid Application Chart
Solenoid
SSA
SSB
SSC
1st
ON
ON ON
ON
ON ON
ON ON
2nd 3rd 4th 5th
MAZDA SOLENOID IDENTIFICATION AND LOCATIONS
Mazda Solenoids
Figure 49
Mazda Solenoids Will Work "Only" On Mazda "6" And
Mazda "MPV"
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
37
Copyright © 2008 ATSGCopyright © 2008 ATSG
Copyright © 2008 ATSG
Copyright © 2008 ATSG
Mazda ON/OFF Solenoids
On/Off Solenoids are as follows:Shift Solenoids A, B, C, High Clutch Timing Solenoid, Reduction Timing Solenoid and the 2/4 Brake Timing Solenoid, as shown in Figure 50 and 51. These On/Off solenoids close the pressure circuit in response to current flow from the TCM. Each solenoid has an internal coil. Current passes through the coil and actuates the needle valve. The needle valve then opens or closes the fluid pressure circuit.
ShiftSolenoid "A"
ShiftSolenoid "B"
ShiftSolenoid "C"
MAZDA "6" AND MAZDA "MPV"ON/OFF
SOLENOID IDENTIFICATION (CONT'D)
High Clutch TimingSolenoid And BrassRetaining Bracket
ReductionTiming Solenoid
2/4 Brake Timing SolenoidAnd Brass Retaining Bracket
MAZDA "6" AND MAZDA "MPV"ON/OFF
Figure 50
Figure 51
Figure 52
Duty Cycle Solenoids are as follows:Line Pressure Solenoid, TCC Solenoid and the Neutral Shift Solenoid, as shown in Figure 52. The duty cycle solenoids repeatedly turn On/Off in 50Hz cycles. This opens or closes the fluid pressure circuit rapidly and allows fluid pressure into the circuit, dependant upon vehicle speed, throttle opening, engine load, and transaxle temperature, among other things. Use the terminal identification and resistance charts on Page 16 for Mazda "6", and Page 17 for Mazda "MPV" to check the solenoids while still in the transaxle.
Neutral ShiftSolenoid
Line PressureSolenoid TCC
Solenoid
MAZDA "6" AND MAZDA "MPV"DUTY CYCLE SOLENOIDS
Mazda Duty Cycle Solenoids
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
23
23
23
D
J C 7 J P
2 1 4 1 2 4
01.09.03D
K
1 2 3 4
5
6
8
9
7
Shift Solenoid Application Chart
Solenoid
N88 = SSA
N89 = SSB
N92 = SSC
1st
ON
ON ON
ON
ON ON
ON ON
2nd 3rd 4th 5th
Description
VW Golf, GTI and Jetta N88 - SV1 N281-SV8 N89-SV2 N92-SV5 N93-SV6 N91-SV4 N90-SV3N283-SV10 N282-SV9
Low ClutchTiming
Solenoid
2-4 BrakeTiming
Solenoid
2-4 BrakeSolenoid
Volkswagen Solenoid Identification And LocationManufacturer
1 2 3 4 5 6 7 8 9
Reduction Timing
Solenoid
ShiftSolenoid
"C"
ShiftSolenoid
"B"
ShiftSolenoid
"A"
TCCSolenoid
LinePressureSolenoid
The Volkswagen solenoid locations and names are identified for you in Figure 53. Notice the familiar "N" numbering on the solenoids instead of names. We have also provided description of solenoid functions in Figure 53.
Manual Valve
Volkswagen Solenoids WillWork "Only" On Volkswagen
VOLKSWAGEN SOLENOID IDENTIFICATION AND LOCATIONS
SOLENOID IDENTIFICATION AND LOCATIONS (CONT'D)Volkswagen Solenoids
38
Copyright © 2008 ATSG
There are a total of nine (9) solenoids, which can be classified as two different types, because of the way in which they operate. Three of them are duty cycle solenoids, the other six are On/Off solenoids. All solenoids are actuated (energized) by a voltage feed from the TCM/ECU.
Figure 53
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
"N88" ShiftSolenoid "A"
"N89" ShiftSolenoid "B"
"N90" Low ClutchTiming Solenoid
"N281" ReductionTiming Solenoid
"N282" 2-4 BrakeTiming Solenoid
"N92" ShiftSolenoid "C"
SOLENOID IDENTIFICATION (CONT'D)Volkswagen ON/OFF Solenoids
On/Off Solenoids are as follows:Shift Solenoids A, B, C, ("N88", "N89", "N92"), the "N90" Solenoid, the "N281" Reduction Timing Solenoid and the "N282 Solenoid, as shown in Figure 54 and 55 These On/Off solenoids close the pressure circuit in response to current flow from the TCM/ECU. Each solenoid has an internal coil. Current passes through the coil and actuates the needle valve. The needle valve then opens and/or closes the fluid pressure circuit.
VOLKSWAGENON/OFF
VOLKSWAGENON/OFF
The "N282" Solenoid and the "N283" Solenoid are placed together and installed into the valve body at the same time, as shown below.
"N282" SOLENOID"N283" SOLENOID
39
Copyright © 2008 ATSGCopyright © 2008 ATSG
Copyright © 2008 ATSG
Figure 54 Figure 56
Figure 55
Volkswagen Duty Cycle Solenoids
Duty Cycle Solenoids are as follows:The "N93" Line Pressure Solenoid, the "N91" TCC Solenoid and the "N283" Solenoid, as shown in Figure 56. The duty cycle solenoids repeatedly turn On/Off in 50Hz cycles. This opens and closes the fluid pressure circuit rapidly and meters the fluid pressure into the circuit, dependant upon vehicle speed, throttle opening, engine load, and transaxle fluid temperature, among other things. Use the terminal identification and resistance charts on Page 21 for Volkswagen, to check the solenoids while still in the transaxle.
"N283" 2-4 BrakeSolenoid
"N93"Line Pressure
Solenoid"N91" TCC
Solenoid
VOLKSWAGENDUTY CYCLE SOLENOIDS
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
40
Copyright © 2008 ATSG
23
23
23
D
J C 7 J P
2 1 4 1 2 4
01.09.03D
K
1 2 3 4
5
6
8
9
7
Shift Solenoid Application Chart
Solenoid
SSA
SSB
SSC
1st
ON
ON ON
ON
ON ON
ON ON
2nd 3rd 4th 5th
Jaguar, X TypeAnd
Land Rover, Freelander
Jaguar/Freelander Solenoid Identification And LocationManufacturer
1 2 3 4 5 6 7 8 9Reduction
TimingSolenoid
ShiftSolenoid
"C"
ShiftSolenoid
"B"
ShiftSolenoid
"A"
2/4 BrakeTiming
Solenoid
2/4 BrakeDuty Solenoid
Low ClutchTiming
Solenoid
TCCSolenoid
LinePressureSolenoid
There are a total of nine (9) solenoids, which can be classified as two different types, because of the way in which they operate. Three of them are duty cycle solenoids, the other six are On/Off solenoids. All solenoids are actuated (energized) by a voltage feed from the TCM/ECU.
JAGUAR/FREELANDER SOLENOID IDENTIFICATION AND LOCATIONS
The Jaguar and Freelander solenoid locations and names are identified for you in Figure 57. The Jaguar and Freelander are the only two units where the solenoids will interchange. Again, the shift solenoid firing sequence is the same on all JF506E transaxles, and is also shown in Figure 57.
SOLENOID IDENTIFICATION AND LOCATIONS (CONT'D)Jaguar/Freelander Solenoids
Figure 57
Jaguar And FreelanderSolenoids Will Work "Only"On Jaguar And Freelander
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
41
ShiftSolenoid "A" Shift
Solenoid "B"
Low ClutchTiming Solenoid
ReductionTiming Solenoid
2/4 BrakeTiming Solenoid
ShiftSolenoid "C"
SOLENOID IDENTIFICATION (CONT'D)Jaguar/Freelander ON/OFF Solenoids
On/Off Solenoids are as follows:Shift Solenoids A, B, C, Low Clutch Timing Solenoid, Reduction Timing Solenoid and the 2/4 Brake Timing Solenoid, as shown in Figure 58 and 59. These On/Off solenoids close the pressure circuit in response to current flow from the TCM/ECU. Each solenoid has an internal coil. Current passes through the coil and actuates the needle valve. The needle valve then opens and/or closes the fluid pressure circuit.
JAGUAR AND FREELANDERON/OFF
JAGUAR AND FREELANDERON/OFF
2/4 BrakeDuty Solenoid
Line PressureSolenoid TCC
Solenoid
JAGUAR AND FREELANDERDUTY CYCLE SOLENOIDS
Jaguar/Freelander Duty Cycle Solenoids
The 2/4 Brake Timing Solenoid and the 2/4 Duty Solenoid are placed together and installed into the valve body at the same time, as shown below.
2/4 BRAKETIMING SOLENOID
2/4 DUTYSOLENOID
Figure 58 Figure 60
Figure 59
Copyright © 2008 ATSGCopyright © 2008 ATSG
Copyright © 2008 ATSG
Duty Cycle Solenoids are as follows:Line Pressure Solenoid, the TCC Solenoid, and the 2-4 Brake Duty Solenoid, as shown in Figure 60. The duty cycle solenoids repeatedly turn On/Off in 50Hz cycles. This opens and closes the fluid pressure circuit rapidly and meters fluid pressure into the circuit, dependant upon vehicle speed, throttle opening, engine load, and transaxle temperature, among other things. Use the terminal identification and resistance charts on Page 25 for the Jaguar, and Page 31 for the Freelander to check the solenoids while still in the transaxle.
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
DTC
Engine Coolant Temperature (ECT) performance problem
Engine Coolant Temperature (ECT) circuit, low input
Engine Coolant Temperature (ECT) circuit, high input
Throttle Position (TP) stuck closed
Throttle Position (TP) circuit, low input
Throttle Position (TP) circuit, high input
Transaxle Range (TR) switch, circuit malfunction (Short to power)
Transaxle Range (TR) switch, circuit malfunction (Open or short)
Transaxle Fluid Temp (TFT) sensor malfunction (Stuck)
Transaxle Fluid Temp (TFT) sensor malfunction (Short circuit)
Transaxle Fluid Temp (TFT) sensor malfunction (Open circuit)
Turbine Shaft Speed (TSS) circuit malfunction
Vehicle Speed Sensor (VSS) circuit malfunction
Torque Converter Clutch (TCC) system malfunction
Torque Converter Clutch (TCC) solenoid malfunction
Pressure Control Solenoid, circuit malfunction
Shift Solenoid "A" malfunction (Stuck Off)
Shift Solenoid "B" malfunction (Stuck Off)
Shift Solenoid "C" malfunction (Stuck Off)
Shift Solenoid "A" malfunction (Stuck On)
Shift Solenoid "B" malfunction (Stuck On)
Shift Solenoid "C" malfunction (Stuck On)
Shift Solenoid "A" malfunction (Open or Short circuit)
Shift Solenoid "B" malfunction (Open or Short circuit)
Shift Solenoid "C" malfunction (Open or Short circuit)
Reduction Timing Solenoid circuit malfunction (Open or Short)
Neutral Shift Solenoid circuit malfunction (Open or Short)
High Clutch Timing Solenoid circuit malfunction (Open or Short)
Ground Return circuit malfunction
CAN BUS OFF
TCM cannot receive signals from PCM
2-4 Brake Timing Solenoid circuit malfunction (Open or Short)
Intermediate Speed Sensor (ISS) circuit malfunction (Open or Short)
P0116
P0117
P0118
P0121
P0122
P0123
P0705
P0706
P0711
P0712
P0713
P0715
P0720
P0740
P0743
P0748
P0751
P0752
P0753
P0756
P0757
P0758
P0761
P0762
P0763
P0768
P0773
P0778
P0791
P0798
P1710
U0073
U0100
MAZDA DIAGNOSTIC TROUBLE CODES
DESCRIPTION
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
No
No
No
No
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
MILON
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
Yes
No
No
No
No
No
No
No
No
No
No
No
No
No
No
ATWARNING
LAMP
42
Copyright © 2008 ATSG
Figure 61
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
Yes
No
No
No
No
No
No
No
No
No
No
No
No
No
No
OD/OFFFLASHING
BOTH MAZDA 6 MAZDA MPV
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
43
Copyright © 2008 ATSG
Figure 62
DTC
N88-SV1 Shift Solenoid A, Circuit Error (Open or Short)
N89-SV2 Shift Solenoid B, Circuit Error (Open or Short)
N92-SV5 Shift Solenoid C, Circuit Error (Open or Short)
N90-SV3 Low Clutch Timing Solenoid, Circuit Error (Open or Short)
N91-SV4 Torque Converter Clutch (TCC) Solenoid, Circuit Error (Open or Short)
N93-SV6 Pressure Control Solenoid, Circuit Error (Open or Short)
G68 Output Speed Sensor (OSS), Vehicle Speed Sensor (VSS), Circuit Fault
Transaxle Range (TR) switch, circuit malfunction (Open or Short circuit)
Kickdown Switch Fault, Wide Open Throttle Signal During Idle
Transaxle Fluid Temperature (TFT) Sensor, Circuit Error (Open or Short Circuit)
N281-SV8 Reduction Timing Solenoid, Circuit Error (Open or Short)
N282-SV9 2-4 Brake Timing Solenoid, Circuit Error (Open or Short)
N283-SV10 2-4 Brake Solenoid, Circuit Error (Open or Short)
Ground Return, Circuit Error (Open or Short)
G265 Intermediate Shaft Speed Sensor, Circuit Fault
TCM to ECM Error, No Speed Signal
Power Supply Voltage Out Of Range
Engine Torque Signal, No Signal or Outside Of Tolerance
Drive Train Data Bus Fault, No Communication
Gear Ratio Error, Mechanical or Electrical
Torque Converter Clutch, Lock-Up Slip, Mechanical or Hydraulic
Engine Control Module, No Comunication or Wrong Equipment
Throttle Position Sensor, No Signal
Selector Lever Lock Solenoid, Circuit Error (Open or Short)
ABS Module, No Communication
Brake Pressure Switch, Implausible Signal
G182 Turbine Shaft Speed Sensor, Circuit Fault
Control Module Faulty, (TCM)
00258
00260
00262
00264
00266
00268
00281
00293
00296
00300
00347
00348
00349
00350
00351
00529
00532
00652
00777
01166
01192
01236
01312
01314
01316
018108
17101
65535
VOLKSWAGEN "VAG" DIAGNOSTIC TROUBLE CODES
DESCRIPTION
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
SPECIAL NOTE: No OBDII correlation available at time of this printing.
44
Copyright © 2008 ATSG
Figure 63
DTC
Engine Coolant Temperature (ECT) Performance Problem
Engine Coolant Temperature (ECT) Circuit, Low Input
Engine Coolant Temperature (ECT) Circuit, High Input
Throttle Position (TP), Performance (TP-1 Compared To TP-2)
Throttle Position (TP) Circuit 1, Low Voltage
Throttle Position (TP) Circuit 1, High Voltage
Transaxle Range (TR) Switch, Circuit Malfunction (Open or short circuit)
Transaxle Fluid Temperature (TFT) Circuit Malfunction
Turbine Shaft Speed (TSS), Circuit Malfunction
Output Speed Sensor (OSS), Circuit Malfunction
Torque Converter Clutch (TCC), System Malfunction
1st Gear Ratio Out Of Range
Reverse Gear Ratio Out Of Range
5th Gear Ratio Out Of Range
4th Gear Ratio Out Of Range
3rd Gear Ratio Out Of Range
2nd Gear Ratio Out Of Range
Torque Converter Clutch (TCC), Solenoid Malfunction
Pressure Control Solenoid, Circuit Malfunction (Open or Short)
Shift Solenoid "A" Malfunction (Open or Short Circuit)
Shift Solenoid "B" Malfunction (Open or Short Circuit)
Shift Solenoid "C" Malfunction (Open or Short Circuit)
J-Gate CAN Network, Circuit Malfunction (Open or Short Circuit)
Solenoid Ground Return, Circuit Malfunction
TCM EEPROM Failure
CAN Torque Reduction Error
Low Clutch Timing Solenoid, Circuit Error (Open or Short)
Reduction Timing Solenoid, Circuit Error (Open or Short)
2-4 Brake Timing Solenoid, Circuit Error (Open or Short)
D-4 Switch, Circuit Error (Open or Short)
Incorrect ECM or TCM Installed In Vehicle
CAN Throttle Angle Error
J-Gate Signal Failure
2-4 Brake Solenoid circuit malfunction (Open or Short circuit)
(TCM Side) Intermediate Speed Sensor (ISS) Circuit Malfunction (Open or Short Circuit)
(ECM Side) Output Speed Sensor (OSS) circuit Malfunction (Open or Short Circuit)
P0116
P0117
P0118
P0121
P0122
P0123
P0706
P0710
P0715
P0720
P0740
P0731
P0736
P0735
P0734
P0733
P0732
P0743
P0748
P0753
P0758
P0763
P0778
P0791
P0791
P0860
P0915
P1573
P1601
P1603
P1710
P1745
P1746
P1747
P1777
P1780
JAGUAR "X" TYPE DIAGNOSTIC TROUBLE CODES
DESCRIPTION
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
45
Figure 64
DTC
Engine Coolant Temperature (ECT) Performance Problem
Engine Coolant Temperature (ECT) Circuit, Short To Ground
Engine Coolant Temperature (ECT) Circuit, Open or Short To Battery
Throttle Position (TP) Circuit 1, Low Voltage
Throttle Position (TP) Circuit 1, High Voltage
Ground Return (Sensor Earth), Short Circuit To Battery
Transaxle Fluid Temperature (TFT) Sensor, Out Of Range
Turbine Shaft Speed (TSS), Circuit Malfunction
Output Speed Sensor (OSS), Circuit Malfunction
Torque Converter Clutch (TCC) Solenoid, Out Of Range
1st Gear Ratio Out Of Range
Reverse Gear Ratio Out Of Range
5th Gear Ratio Out Of Range
4th Gear Ratio Out Of Range
3rd Gear Ratio Out Of Range
2nd Gear Ratio Out Of Range
Torque Converter Clutch (TCC) Solenoid, Short To Ground or Power
Pressure Control Solenoid, Circuit Malfunction (Open or Short)
Shift Solenoid "A" Malfunction (Open or Short Circuit)
Shift Solenoid "B" Malfunction (Open or Short Circuit)
Shift Solenoid "C" Malfunction (Open or Short Circuit)
Intermediate Shaft Speed Sensor, Circuit Malfunction
Steptronic (Manual) +/- Switch, Multiple Input Signals or No Signals
Reduction Timing Solenoid, Circuit Error (Open or Short)
Low Clutch Timing Solenoid, Circuit Error (Open or Short)
2-4 Brake Timing Solenoid, Circuit Error (Open or Short)
Flag Error Set For RPM, ECT, TPS, Virtual Throttle Angle or;Torque Reduction Volume Not Achieved
Timeout Monitoring, Missing Nodes Detected
Level Monitoring Incompatable
BUS Monitoring Off
CAN BUS Malfunction
Shift Interlock, ECU Shift Interlock Failure
EAT ECU EEPROM Error, Flag Set
Battery Voltage, Out Of Range
Mode Switch Input, Multiple Signals
P0116
P0117
P0118
P0122
P0123
P0702
P0710
P0715
P0720
P0740
P0731
P0736
P0735
P0734
P0733
P0732
P0743
P0748
P0753
P0758
P0763
P0790
P1605
P1562
P1715
P1748
P1785
P1786
P1815
P1844
P1843
P1842
P1841
P1840
P1825
LAND ROVER FREELANDER DIAGNOSTIC TROUBLE CODES
DESCRIPTION
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
46
Figure 65
23
8021
204N PM
-SUB
JC7JP
-1
FF
12
2
2
2
2
4
4
4
5
5
5
5
64
60
5
10
12
11
14
16
17 18
19
20
6221
27
29
31
30
27 26
25
24
23
22
28
15
13
8
6
6
6
6
6
7
3
3
61
MAZDA JF506 VALVE BODY EXPLODED VIEW
See Legend In Figure 67
6
3
43
45
9
Copyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
47
Copyright © 2008 ATSG
23
8021
204N PM
-SUB
JC7JP
-1
FF
60
64
21
11
3233
39
40
42 41
35
36
37
44
46
47
48
49
2
26
34
5
5
5
12
15
64
63
Figure 66
See Legend In Figure 67
MAZDA JF506 "SUB LOWER" AND "LOWER" VALVE BODY EXPLODED VIEW
38
34
Sub LowerValve Body
LowerValve Body
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
48
Copyright © 2008 ATSG
50
51
52
53
5455
56
57
58
59
25
26
1 VALVE BODY BRACKET 2 VALVE BODY BOLT, 37MM LENGTH 3 NUT FOR VALVE BODY BOLT FROM BOTTOM 4 VALVE BODY BOLT, 67MM LENGTH 5 VALVE BODY BOLT, 90MM LENGTH 6 VALVE BODY BOLT, 24MM LENGTH 7 LINE PRESSURE SOLENOID (DUTY CYCLE) 8 HIGH CLUTCH TIMING SOLENOID (ON/OFF) 9 NEUTRAL SHIFT SOLENOID (DUTY CYCLE) 10 2/4 BRAKE TIMING SOLENOID (ON/OFF) 11 SUB LOWER VALVE BODY CASTING 12 PILOT FILTER WITH "LEAF" SPRING 13 SPACER PLATE "A" WITH GASKETS 14 2/4 BRAKE TIMING SOLENOID BRASS RETAINING BRACKET 15 COIL SPRING LOADED FILTERS (2 REQUIRED) 16 TCC SOLENOID (DUTY CYCLE) 17 SHIFT SOLENOID "A" (ON/OFF) 18 REDUCTION TIMING SOLENOID (ON/OFF) 19 SHIFT SOLENOID "B" (ON/OFF) 20 SHIFT SOLENOID "C" (ON/OFF) 21 LOWER VALVE BODY CASTING 22 MANUAL SHIFT VALVE 23 SPACER PLATE "B" (NO GASKETS USED) 24 INTERNAL VALVE BODY CASTING 25 PLASTIC CHECK BALL (.218" DIAMETER, 5 REQUIRED) 26 STEEL CHECK BALL (.218" DIAMETER, 4 REQUIRED) 27 INTERNAL VALVE BODY FLAT SCREEN (2 REQUIRED) 28 SPACER PLATE "C" WITH BONDED GASKETS 29 HIGH CLUTCH TIMING SOLENOID BRASS RETAINING BRACKET 30 PLASTIC CHECK BALL (.218" DIAMETER, 4 REQUIRED) 31 UPPER VALVE BODY CASTING 32 MODIFIER ACCUMULATOR VALVE TRAIN
33 PRESSURE MODIFIER VALVE TRAIN 34 TORQUE CONVERTER PRESSURE REGULATOR VALVE TRAIN 35 THROTTLE ACCUMULATOR "A" VALVE TRAIN 36 ACCUMULATOR CONTROL VALVE "A" VALVE TRAIN 37 THROTTLE ACCUMULATOR "C" VALVE TRAIN 38 ACCUMULATOR CONTROL VALVE "C" VALVE TRAIN 39 REDUCTION REDUCING VALVE TRAIN 40 REDUCTION TIMING VALVE TRAIN 41 LINE PRESSURE RELIEF BALL AND SPRING 42 PRESSURE REGULATOR VALVE TRAIN 43 VALVE BODY BOLT, 75MM LENGTH (BLACK IN COLOR) 44 ACCUMULATOR CONTROL VALVE "B" VALVE TRAIN 45 VALVE BODY BOLT, 105.5MM LENGTH (BLACK IN COLOR) 46 THROTTLE ACCUMULATOR "B" VALVE TRAIN 47 HIGH CLUTCH ACCUMULATOR PISTON AND SPRING 48 LOW CLUTCH ACCUMULATOR PISTON AND SPRING 49 SHIFT VALVE "C" VALVE TRAIN 50 SHIFT VALVE "A" VALVE TRAIN 51 TCC CONTROL VALVE TRAIN 52 NEUTRAL SHIFT VALVE TRAIN 53 MANUAL SHIFT VALVE 54 PILOT VALVE TRAIN 55 ACCUMULATOR SWITCH VALVE TRAIN 56 NEUTRAL CONTROL VALVE TRAIN 57 REVERSE INHIBIT VALVE TRAIN 58 SHIFT VALVE "B" VALVE TRAIN 59 FAILSAFE VALVE TRAIN 60 INTERNAL CONNECTOR RETAINING BRACKET 61 INTERNAL SOLENOID WIRE HARNESS CLIP 62 INTERNAL SPEED SENSOR WIRE HARNESS CLIP 63 INTERNAL SPEED SENSOR WIRE HARNESS CLIP 64 VALVE BODY TO CASE BOLT, 90MM LONG (SILVER IN COLOR)
Figure 67
MAZDA JF506 "INTERNAL" VALVE BODY EXPLODED VIEW
27
24
InternalValve Body
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
F
49
Copyright © 2008 ATSG
= Steel Ball .218" Diameter
= Plastic Ball .218" Diameter
MAZDA SMALL PARTS AND CHECKBALL LOCATIONS
Figure 68
"Leaf Spring"Faces Down
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
50
Copyright © 2008 ATSG
23
01
.09.03
DJC
7JP
DD
214124
23
23
DD
1
2
2
2
2
2
4
4
4
5 5
5
5
9
10
12
11
14
16
17
18
19
20
6221
29
31
30
27
26
25
24
23
22
28
15
13
58
6
6
6
7
3
3
3
61
VOLKSWAGEN JF506 VALVE BODY EXPLODED VIEW
Figure 69
See Legend In Figure 71
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
23
01
.09.03
DJC
7JP
DD
214124
23
23
DD
21
11
3233
39
40
42 41
34
35
36
37
43
44
45
46
47
48
49
38
2
2
6
34
5
5
5
12
15
60
64
63
VOLKSWAGEN JF506 VALVE BODY EXPLODED VIEW
Figure 70
See Legend In Figure 71
51
Copyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
50
51
52
53
5455
56
57
58
59
25
26
1 VALVE BODY BRACKET 2 VALVE BODY BOLT, 37MM LENGTH 3 NUT FOR VALVE BODY BOLT FROM BOTTOM 4 VALVE BODY BOLT, 67MM LENGTH 5 VALVE BODY BOLT, 90MM LENGTH 6 VALVE BODY BOLT, 22MM LENGTH 7 LINE PRESSURE SOLENOID (N93-SV6) 8 LOW CLUTCH TIMING SOLENOID (N90-SV3) 9 2-4 BRAKE TIMING SOLENOID (N282-SV9) 10 2-4 BRAKE DUTY SOLENOID (N283-SV10) 11 SUB LOWER VALVE BODY CASTING 12 PILOT FILTER WITH "LEAF" SPRING 13 SPACER PLATE "A" WITH GASKETS 14 OIL BAFFLE 15 COIL SPRING LOADED FILTERS (2 REQUIRED) 16 TCC SOLENOID (N91-SV4) 17 SHIFT SOLENOID "A" (N88-SV1) 18 REDUCTION TIMING SOLENOID (N281-SV8) 19 SHIFT SOLENOID "B" (N89-SV2) 20 SHIFT SOLENOID "C" (N92-SV5) 21 LOWER VALVE BODY CASTING 22 MANUAL SHIFT VALVE 23 SPACER PLATE "B" (NO GASKETS) 24 INTERNAL VALVE BODY CASTING 25 PLASTIC CHECK BALL (.218" DIAMETER, 5 REQUIRED) 26 STEEL CHECK BALL (.218" DIAMETER, 4 REQUIRED) 27 SPACER PLATE "C" UPPER GASKET (MAY BE BONDED) 28 SPACER PLATE "C" 29 SPACER PLATE "C" LOWER GASKET (MAY BE BONDED) 30 PLASTIC CHECK BALL (.218" DIAMETER, 4 REQUIRED) 31 UPPER VALVE BODY CASTING 32 MODIFIER ACCUMULATOR VALVE TRAIN
33 PRESSURE MODIFIER VALVE TRAIN 34 TORQUE CONVERTER PRESSURE REGULATOR VALVE TRAIN 35 THROTTLE ACCUMULATOR VALVE "A" VALVE TRAIN 36 ACCUMULATOR CONTROL VALVE "A" VALVE TRAIN 37 HIGH CLUTCH ACCUMULATOR REGULATOR VALVE TRAIN 38 2-4 BRAKE CLUTCH ACCUMULATOR REGULATOR VALVE TRAIN 39 REDUCTION REDUCING VALVE TRAIN 40 REDUCTION TIMING VALVE TRAIN 41 LINE PRESSURE RELIEF BALL AND SPRING 42 PRESSURE REGULATOR VALVE TRAIN 43 2-4 CLUTCH ACCUMULATOR REGULATOR SWITCH VALVE TRAIN 44 ACCUMULATOR CONTROL VALVE "B" VALVE TRAIN 45 HIGH CLUTCH ACCUMULATOR REGULATOR SWITCH VALVE 46 THROTTLE ACCUMULATOR "B" VALVE TRAIN 47 HIGH CLUTCH ACCUMULATOR PISTON AND SPRING 48 LOW CLUTCH ACCUMULATOR PISTON AND SPRING 49 SHIFT VALVE "C" VALVE TRAIN 50 SHIFT VALVE "A" VALVE TRAIN 51 TCC CONTROL VALVE TRAIN 52 NEUTRAL SHIFT VALVE TRAIN 53 MANUAL SHIFT VALVE 54 PILOT VALVE TRAIN 55 ACCUMULATOR SWITCH VALVE TRAIN 56 NEUTRAL CONTROL VALVE TRAIN 57 REVERSE INHIBIT VALVE TRAIN 58 SHIFT VALVE "B" VALVE TRAIN 59 FAILSAFE VALVE TRAIN 60 INTERNAL SOLENOID WIRE HARNESS CLIP 61 INTERNAL SOLENOID WIRE HARNESS CLIP 62 INTERNAL SPEED SENSOR WIRE HARNESS CLIP 63 INTERNAL SPEED SENSOR WIRE HARNESS CLIP 64 VALVE BODY TO CASE BOLT, 90MM LONG (SILVER IN COLOR)
VOLKSWAGEN JF506 VALVE BODY EXPLODED VIEW
Figure 71
52
Copyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
D
= Steel Ball .218" Diameter
= Plastic Ball .218" Diameter
VOLKSWAGEN SMALL PARTS AND CHECKBALL LOCATIONS
Copyright © 2007 ATSG
"Leaf Spring"Faces Down
53
Copyright © 2008 ATSG
Figure 72
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
23
01
.09.03
DJC
7JP
DD
214124
23
23
DD
1
2
2
2
2
2
4
4
4
5 5
5
5
9
10
12
11
14
16
17
18
19
20
6221
31
30
26
25
24
23
22
28
15
13
58
6
6
6
7
3
3
3
61
JAGUAR JF506 VALVE BODY EXPLODED VIEW
Figure 73
See Legend In Figure 75
54
Copyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
23
01
.09.03
DJC
7JP
DD
214124
23
23
DD
21
11
3233
39
40
42 41
34
35
36
37
43
44
45
46
47
48
49
38
2
2
6
34
5
5
5
12
15
60
64
64
63
JAGUAR JF506 VALVE BODY EXPLODED VIEW
Figure 74
See Legend In Figure 75
27
61
62
55
Copyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
50
51
52
53
5455
56
57
58
59
25
26
33 PRESSURE MODIFIER VALVE TRAIN 34 TCC PRESSURE REGULATOR VALVE TRAIN 35 THROTTLE ACCUMULATOR VALVE "A" VALVE TRAIN 36 ACCUMULATOR CONTROL VALVE "A" VALVE TRAIN 37 HIGH CLUTCH ACCUMULATOR REGULATOR VALVE TRAIN 38 2-4 BRAKE CLUTCH ACCUMULATOR REGULATOR VALVE TRAIN 39 REDUCTION REDUCING VALVE TRAIN 40 REDUCTION TIMING VALVE TRAIN 41 LINE PRESSURE RELIEF BALL AND SPRING 42 PRESSURE REGULATOR VALVE TRAIN 43 2-4 CLUTCH ACCUMULATOR REGULATOR SWITCH VALVE TRAIN 44 ACCUMULATOR CONTROL VALVE "B" VALVE TRAIN 45 HIGH CLUTCH ACCUMULATOR REGULATOR SWITCH VALVE 46 THROTTLE ACCUMULATOR "B" VALVE TRAIN 47 HIGH CLUTCH ACCUMULATOR PISTON AND SPRING 48 LOW CLUTCH ACCUMULATOR PISTON AND SPRING 49 SHIFT VALVE "C" VALVE TRAIN 50 SHIFT VALVE "A" VALVE TRAIN 51 TCC CONTROL VALVE TRAIN 52 NEUTRAL SHIFT VALVE TRAIN 53 MANUAL SHIFT VALVE 54 PILOT VALVE TRAIN 55 ACCUMULATOR SWITCH VALVE TRAIN 56 NEUTRAL CONTROL VALVE TRAIN 57 REVERSE INHIBIT VALVE TRAIN 58 SHIFT VALVE "B" VALVE TRAIN 59 FAILSAFE VALVE TRAIN 60 INTERNAL SOLENOID WIRE HARNESS CLIP 61 INTERNAL SOLENOID WIRE HARNESS CLIP 62 INTERNAL SPEED SENSOR WIRE HARNESS CLIP 63 INTERNAL SPEED SENSOR WIRE HARNESS CLIP 64 VALVE BODY TO CASE BOLT, 90MM LONG (SILVER IN COLOR)
JAGUAR JF506 VALVE BODY EXPLODED VIEW
Figure 75
1 VALVE BODY BRACKET 2 VALVE BODY BOLT, 37MM LENGTH 3 NUT FOR VALVE BODY BOLT FROM BOTTOM 4 VALVE BODY BOLT, 67MM LENGTH 5 VALVE BODY BOLT, 90MM LENGTH 6 VALVE BODY BOLT, 22MM LENGTH 7 LINE PRESSURE SOLENOID (DUTY CYCLE) 8 LOW CLUTCH TIMING SOLENOID (ON/OFF) 9 2-4 BRAKE TIMING SOLENOID (ON/OFF) 10 2-4 BRAKE DUTY SOLENOID (DUTY CYCLE) 11 SUB LOWER VALVE BODY CASTING 12 PILOT FILTER WITH "LEAF" SPRING 13 SPACER PLATE "A" WITH GASKETS 14 OIL BAFFLE 15 COIL SPRING LOADED FILTERS (2 REQUIRED) 16 TCC SOLENOID (DUTY CYCLE) 17 SHIFT SOLENOID "A" (ON/OFF) 18 REDUCTION TIMING SOLENOID (ON/OFF) 19 SHIFT SOLENOID "B" (ON/OFF) 20 SHIFT SOLENOID "C" (ON/OFF) 21 LOWER VALVE BODY CASTING 22 MANUAL SHIFT VALVE 23 SPACER PLATE "B" (NO GASKETS) 24 INTERNAL VALVE BODY CASTING 25 PLASTIC CHECK BALL (.218" DIAMETER, 5 REQUIRED) 26 STEEL CHECK BALL (.218" DIAMETER, 4 REQUIRED) 27 HARNESS CONNECTOR SUPPORT BRACKET. 28 SPACER PLATE "C" WITH BONDED GASKETS 30 PLASTIC CHECK BALL (.218" DIAMETER, 3 REQUIRED) 31 UPPER VALVE BODY CASTING 32 MODIFIER ACCUMULATOR VALVE TRAIN
56
Copyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
D
= Steel Ball .218" Diameter
= Plastic Ball .218" Diameter
JAGUAR SMALL PARTS AND CHECKBALL LOCATIONS
Copyright © 2007 ATSG
"Leaf Spring"Faces Down
Figure 76
57
Copyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
23
01
.09.03
DJC
7JP
DD
214124
23
23
DD
1
2
2
2
2
2
4
4
4
5 5
5
5
9
10
12
11
14
16
17
18
19
20
6221
31
30
26
25
24
23
22
28
15
13
58
6
6
6
7
3
3
3
61
FREELANDER JF506 VALVE BODY EXPLODED VIEW
Figure 77
See Legend In Figure 79
58
Copyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
23
01
.09.03
DJC
7JP
DD
214124
23
23
DD
21
11
3233
39
40
42 41
34
35
36
37
43
44
45
46
47
48
49
38
2
2
6
34
5
5
5
12
15
60
64
64
63
FREELANDER JF506 VALVE BODY EXPLODED VIEW
Figure 78
See Legend In Figure 79
27
61
62
59
Copyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
50
51
52
53
5455
56
57
58
59
25
26
33 PRESSURE MODIFIER VALVE TRAIN 34 TCC PRESSURE REGULATOR VALVE TRAIN 35 THROTTLE ACCUMULATOR VALVE "A" VALVE TRAIN 36 ACCUMULATOR CONTROL VALVE "A" VALVE TRAIN 37 HIGH CLUTCH ACCUMULATOR REGULATOR VALVE TRAIN 38 2-4 BRAKE CLUTCH ACCUMULATOR REGULATOR VALVE TRAIN 39 REDUCTION REDUCING VALVE TRAIN 40 REDUCTION TIMING VALVE TRAIN 41 LINE PRESSURE RELIEF BALL AND SPRING 42 PRESSURE REGULATOR VALVE TRAIN 43 2-4 CLUTCH ACCUMULATOR REGULATOR SWITCH VALVE TRAIN 44 ACCUMULATOR CONTROL VALVE "B" VALVE TRAIN 45 HIGH CLUTCH ACCUMULATOR REGULATOR SWITCH VALVE 46 THROTTLE ACCUMULATOR "B" VALVE TRAIN 47 HIGH CLUTCH ACCUMULATOR PISTON AND SPRING 48 LOW CLUTCH ACCUMULATOR PISTON AND SPRING 49 SHIFT VALVE "C" VALVE TRAIN 50 SHIFT VALVE "A" VALVE TRAIN 51 TCC CONTROL VALVE TRAIN 52 NEUTRAL SHIFT VALVE TRAIN 53 MANUAL SHIFT VALVE 54 PILOT VALVE TRAIN 55 ACCUMULATOR SWITCH VALVE TRAIN 56 NEUTRAL CONTROL VALVE TRAIN 57 REVERSE INHIBIT VALVE TRAIN 58 SHIFT VALVE "B" VALVE TRAIN 59 FAILSAFE VALVE TRAIN 60 INTERNAL SOLENOID WIRE HARNESS CLIP 61 INTERNAL SOLENOID WIRE HARNESS CLIP 62 INTERNAL SPEED SENSOR WIRE HARNESS CLIP 63 INTERNAL SPEED SENSOR WIRE HARNESS CLIP 64 VALVE BODY TO CASE BOLT, 90MM LONG (SILVER IN COLOR)
FREELANDER JF506 VALVE BODY EXPLODED VIEW
Figure 79
1 VALVE BODY BRACKET 2 VALVE BODY BOLT, 37MM LENGTH 3 NUT FOR VALVE BODY BOLT FROM BOTTOM 4 VALVE BODY BOLT, 67MM LENGTH 5 VALVE BODY BOLT, 90MM LENGTH 6 VALVE BODY BOLT, 22MM LENGTH 7 LINE PRESSURE SOLENOID (DUTY CYCLE) 8 LOW CLUTCH TIMING SOLENOID (ON/OFF) 9 2-4 BRAKE TIMING SOLENOID (ON/OFF) 10 2-4 BRAKE DUTY SOLENOID (DUTY CYCLE) 11 SUB LOWER VALVE BODY CASTING 12 PILOT FILTER WITH "LEAF" SPRING 13 SPACER PLATE "A" WITH GASKETS 14 OIL BAFFLE 15 COIL SPRING LOADED FILTERS (2 REQUIRED) 16 TCC SOLENOID (DUTY CYCLE) 17 SHIFT SOLENOID "A" (ON/OFF) 18 REDUCTION TIMING SOLENOID (ON/OFF) 19 SHIFT SOLENOID "B" (ON/OFF) 20 SHIFT SOLENOID "C" (ON/OFF) 21 LOWER VALVE BODY CASTING 22 MANUAL SHIFT VALVE 23 SPACER PLATE "B" (NO GASKETS) 24 INTERNAL VALVE BODY CASTING 25 PLASTIC CHECK BALL (.218" DIAMETER, 5 REQUIRED) 26 STEEL CHECK BALL (.218" DIAMETER, 4 REQUIRED) 27 HARNESS CONNECTOR SUPPORT BRACKET. 28 SPACER PLATE "C" WITH BONDED GASKETS 30 PLASTIC CHECK BALL (.218" DIAMETER, 3 REQUIRED) 31 UPPER VALVE BODY CASTING 32 MODIFIER ACCUMULATOR VALVE TRAIN
60
Copyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
D
= Steel Ball .218" Diameter
= Plastic Ball .218" Diameter
FREELANDER SMALL PARTS AND CHECKBALL LOCATIONS
"Leaf Spring"Faces Down
Figure 80
61
Copyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
Mazda
Code Code
Volkswagen/Jaguar/Freelander
SPACER PLATE "A" IDENTIFICATION
62
Copyright © 2008 ATSG
Figure 81
SPACER PLATE DIFFERENCES
Spacer Plate "A"
Spacer Plate "B"
Spacer Plate "C"
Spacer Plate "A" is the smallest of the three, uses bonded gaskets, and is illustrated in Figure 81. Spacer Plate "A" goes between the lower valve body and the sub lower valve body. Volkswagen, Jaguar and Freelander all use the same plate, as shown in Figure 81. The Mazda plate is different and will work only with Mazda valve bodies. Pay close attention to the codes that are stamped into the plates, as shown in Figure 81, as they will not interchange.
Spacer Plate "B" is the largest of the three, uses no gaskets, and is illustrated in Figure 82. Spacer plate "B" goes between the lower valve body and the internal valve body, and is the one that can get you in the most trouble. The manufacturer has made them very easy to identify, as shown in Figure 82. The Mazda uses the "A" plate, Volkswagen uses the "K" plate, Jaguar uses the "J" plate, and Freelander uses the "F" plate. Pay attention to the codes, as these spacer plates will not interchange between the models.
Spacer Plate "C" is the mid-size of the three, uses bonded gaskets, and is illustrated in Figure 83. Spacer plate "C" goes between the upper valve body and the internal valve body. The manufacturer has made them very easy to identify, as shown in Figure 83, with the codes stamped into the plates. These spacer plates will not interchange between the models, with the exception of the Jaguar and Freelander.
The spacer plates in the JF506E units are very similar, but they will not all interchange. You must pay attention to the codes that are stamped into the spacer plates. Some are enough different that they would only affect calibration concerns, but others would affect transaxle operation.
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
SPACER PLATE "B" IDENTIFICATION
Mazda
Code"A"
Code"K"
Volkswagen
Code"F"
FreelanderJaguar
Code"J"
63
Copyright © 2008 ATSG
Figure 82
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
Mazda
Jaguar/Freelander
Volkswagen
SPACER PLATE "C" IDENTIFICATION
Code
Code Code
64
Copyright © 2008 ATSG
Figure 83
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
FF
23
8021
204N PM
-SUB
JC7JP
-1
65
Copyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
23
23
DD
23
01
.09.03
DJC
7JP
DD
214124
SUB LOWER AND LOWER VALVE BODY CASTING IDENTIFICATION
VALVE BODY CASTING IDENTIFICATION
MAZDA VOLKSWAGEN, JAGUARAND FREELANDER
"F" Casting
FlatScreen
NoScreen
"F" Casting
"D" Casting
"D" Casting
TubeNo Tube
Solenoid MountDifferent
Solenoid MountDifferent
Figure 84
Sub Lower Valve Body Lower Valve Body
Sub LowerValve Body
LowerValve Body
Sub LowerValve Body
LowerValve Body
The Sub Lower Valve Body has different worm tracks, one uses a tube and one does not, and the mount for the solenoids is different, as shown in Figure 84. The easiest identification is the "F" cast into the Mazda valve body, and the "D" cast into the Volkswagen, Jaguar and Freelander valve body, as shown in Figure 84.
The Lower Valve Body has different worm tracks, one uses a flat screen and one does not, as shown in Figure 84. The easiest identification is the "F" cast into the Mazda valve body, and the "D" cast into the Volkswagen, Jaguar and Freelander valve body, as shown in Figure 84.
Copyright © 2008 ATSG
66 AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
Figure 85
INTERNAL VALVE BODY CASTING IDENTIFICATION
MAZDA VOLKSWAGEN, JAGUARAND FREELANDER
VALVE BODY CASTING IDENTIFICATION (CONT'D)Internal Valve Body
The Internal Valve Body has different worm tracks, one uses a flat screen and one does not, as shown in Figure 85. We have also high-lighted for you, the worm tracks that are different, also shown in Figure 85.
67
Copyright © 2008 ATSG
JF506E MazdaValve Body
JF506E VolkswagenJaguar, Freelander
Valve Body
23
23
23
D
J C 7 J P
2 1 4 1 2 4
01.09.03D
K
2
2
2
2
2
2
2 2 2
22
23PM-SUB
F
JC7 JP
B021204N
-1
K
2
2
2
2
2
2
2 2
2
2
3
VALVE BODY TO CASE BOLT LOCATIONS FREELANDER VALVE BODY ASSEMBLY
Figure 86
2. VALVE BODY TO CASE BOLT, 90MM LONG (SILVER IN COLOR) TEN 90MM LONG BOLTS REQUIRED 3. VALVE BODY TO CASE BOLT, 106MM LONG (SILVER IN COLOR) ONE 106MM LONG BOLT REQUIRED
2. VALVE BODY TO CASE BOLT, 90MM LONG (SILVER IN COLOR) ELEVEN 90MM LONG BOLTS REQUIRED
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
Valve body to case retaining bolt locations are shown in Figure 86, for all models. The valve body to case bolts are Silver in color, all others are Gold.
The following Pages will begin the valve body assembly process for the Freelander. All others are very similar.
23
01
.09.03
DJC
7JP
DD
214124
23
23
DD
1
2
2
2
2
2
4
4
4
5 5
5
5
9
10
12
11
14
16
17
18
19
20
6221
31
30
26
25
24
23
22
28
15
13
58
6
6
6
7
3
3
3
61
FREELANDER JF506 VALVE BODY EXPLODED VIEW
Figure 87
See Legend In Figure 89
Copyright © 2008 ATSG
68 AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
23
01
.09.03
DJC
7JP
DD
214124
23
23
DD
21
11
3233
39
40
42 41
34
35
36
37
43
44
45
46
47
48
49
38
2
2
6
34
5
5
5
12
15
60
64
64
63
FREELANDER JF506 VALVE BODY EXPLODED VIEW
Figure 88
See Legend In Figure 89
27
61
62
69
Copyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
50
51
52
53
5455
56
57
58
59
25
26
33 PRESSURE MODIFIER VALVE TRAIN 34 TCC PRESSURE REGULATOR VALVE TRAIN 35 THROTTLE ACCUMULATOR VALVE "A" VALVE TRAIN 36 ACCUMULATOR CONTROL VALVE "A" VALVE TRAIN 37 HIGH CLUTCH ACCUMULATOR REGULATOR VALVE TRAIN 38 2-4 BRAKE CLUTCH ACCUMULATOR REGULATOR VALVE TRAIN 39 REDUCTION REDUCING VALVE TRAIN 40 REDUCTION TIMING VALVE TRAIN 41 LINE PRESSURE RELIEF BALL AND SPRING 42 PRESSURE REGULATOR VALVE TRAIN 43 2-4 CLUTCH ACCUMULATOR REGULATOR SWITCH VALVE TRAIN 44 ACCUMULATOR CONTROL VALVE "B" VALVE TRAIN 45 HIGH CLUTCH ACCUMULATOR REGULATOR SWITCH VALVE 46 THROTTLE ACCUMULATOR "B" VALVE TRAIN 47 HIGH CLUTCH ACCUMULATOR PISTON AND SPRING 48 LOW CLUTCH ACCUMULATOR PISTON AND SPRING 49 SHIFT VALVE "C" VALVE TRAIN 50 SHIFT VALVE "A" VALVE TRAIN 51 TCC CONTROL VALVE TRAIN 52 NEUTRAL SHIFT VALVE TRAIN 53 MANUAL SHIFT VALVE 54 PILOT VALVE TRAIN 55 ACCUMULATOR SWITCH VALVE TRAIN 56 NEUTRAL CONTROL VALVE TRAIN 57 REVERSE INHIBIT VALVE TRAIN 58 SHIFT VALVE "B" VALVE TRAIN 59 FAILSAFE VALVE TRAIN 60 INTERNAL SOLENOID WIRE HARNESS CLIP 61 INTERNAL SOLENOID WIRE HARNESS CLIP 62 INTERNAL SPEED SENSOR WIRE HARNESS CLIP 63 INTERNAL SPEED SENSOR WIRE HARNESS CLIP 64 VALVE BODY TO CASE BOLT, 90MM LONG (SILVER IN COLOR)
FREELANDER JF506 VALVE BODY EXPLODED VIEW
Figure 89
1 VALVE BODY BRACKET 2 VALVE BODY BOLT, 37MM LENGTH 3 NUT FOR VALVE BODY BOLT FROM BOTTOM 4 VALVE BODY BOLT, 67MM LENGTH 5 VALVE BODY BOLT, 90MM LENGTH 6 VALVE BODY BOLT, 22MM LENGTH 7 LINE PRESSURE SOLENOID (DUTY CYCLE) 8 LOW CLUTCH TIMING SOLENOID (ON/OFF) 9 2-4 BRAKE TIMING SOLENOID (ON/OFF) 10 2-4 BRAKE DUTY SOLENOID (DUTY CYCLE) 11 SUB LOWER VALVE BODY CASTING 12 PILOT FILTER WITH "LEAF" SPRING 13 SPACER PLATE "A" WITH GASKETS 14 OIL BAFFLE 15 COIL SPRING LOADED FILTERS (2 REQUIRED) 16 TCC SOLENOID (DUTY CYCLE) 17 SHIFT SOLENOID "A" (ON/OFF) 18 REDUCTION TIMING SOLENOID (ON/OFF) 19 SHIFT SOLENOID "B" (ON/OFF) 20 SHIFT SOLENOID "C" (ON/OFF) 21 LOWER VALVE BODY CASTING 22 MANUAL SHIFT VALVE 23 SPACER PLATE "B" (NO GASKETS) 24 INTERNAL VALVE BODY CASTING 25 PLASTIC CHECK BALL (.218" DIAMETER, 5 REQUIRED) 26 STEEL CHECK BALL (.218" DIAMETER, 4 REQUIRED) 27 HARNESS CONNECTOR SUPPORT BRACKET. 28 SPACER PLATE "C" WITH BONDED GASKETS 30 PLASTIC CHECK BALL (.218" DIAMETER, 3 REQUIRED) 31 UPPER VALVE BODY CASTING 32 MODIFIER ACCUMULATOR VALVE TRAIN
70
Copyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
71
Copyright © 2008 ATSG
FREELANDER VALVE BODY ASSEMBLY (CONT'D)FREELANDER VALVE BODY ASSEMBLY
1. Disassemble the valve body assembly using Figure 87 as a guide. Note: Tag the High and Low Accumulator piston springs as you remove them, as there are different calibrations, and no information available for identification. 2. Clean valve body component parts thoroughly and dry with compressed air. 3. Starting with the sub lower valve body, shown in Figure 90, disassemble and place the valves, springs, bore plugs and retainers in appropriate trays exactly as they were removed. 4. Clean sub lower valve body parts thoroughly and dry with compressed air. 5. Assemble sub lower valve body parts exactly as shown in Figure 90, and lube with ATF as they are installed. Note: Install the retainers exactly as shown in Figure 90, as they install in different directions through out the valve body.
Sub LowerValve Body
6
6
Figure 90
02.95
OFF
RPM
RPMCOMmAA
10A MaxFUSED
V
V
mVW
W
W
VmAA
mAA
DCAUTO
FLUKE 88
Copyright © 2008 ATSG
Figure 91
Resistance Should Be2.6 to 3.2 Ohms
Continued on Page 72
23
01
.09.03
DJC
7JP
DD
214124
11
3233
34
35
36
37
38
6 VALVE BODY BOLT, 22MM LENGTH 7 LINE PRESSURE SOLENOID (DUTY CYCLE) 11 SUB LOWER VALVE BODY CASTING 32 MODIFIER ACCUMULATOR VALVE TRAIN 33 PRESSURE MODIFIER VALVE TRAIN 34 TCC PRESSURE REGULATOR VALVE TRAIN 35 THROTTLE ACCUMULATOR VALVE "A" VALVE TRAIN 36 ACCUMULATOR CONTROL VALVE "A" VALVE TRAIN 37 HIGH CLUTCH ACCUMULATOR REGULATOR VALVE TRAIN 38 2-4 BRAKE CLUTCH ACCUMULATOR REGULATOR VALVE TRAIN
The following procedure is dedicated to the Land Rover, Freelander valve body, but all other valve bodies are very similar and the same procedure can be used, as long as correct spacer plates are used. There are two different colors of valve body bolts, Silver and Gold. Silver in color bolts are the valve body to case bolts. Gold in color, all other locations.
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
Number 37.............. Large Dia. = .447", Small Dia. = .396".
I.D. GROOVEFACES BORE PLUGDOUBLE
I.D. GROOVE
SMALL ENDGOES IN 1ST
37
VALVE LINE-UP, BORE NUMBER 37
Number 38.............. Large Dia. = .388", Small Dia. = .365".
38
END VIEW OF DEEPSLOTTED END OF
SLEEVE FROM NO. 38
I.D. GROOVEFACES BORE PLUG
SINGLEI.D. GROOVE
SMALL ENDGOES IN 1ST
VALVE LINE-UP, BORE NUMBER 38
37 HIGH CLUTCH ACCUMULATOR REGULATOR VALVE TRAIN 38 2-4 BRAKE CLUTCH ACCUMULATOR REGULATOR VALVE TRAIN
23
01
.09.03
DJC
7JP
DD
214124
37
38
FREELANDER VALVE BODY ASSEMBLY (CONT'D)
Continued on Page 73
72
Special Caution:
Figure 92
Figure 93 Figure 94
6. Bore numbers 37 and 38, shown in Figure 92, are almost identical, when inspecting visually, but the diameter of the valves inside of the sleeves are different. The valve lands are also different diameters on the same valve. Refer to Figure 93 and 94 for the valve diameters and identification grooves. 7. The sleeves both have the same O.D. which means they will not interchange, even though they fit in the bore. The sleeve from bore No. 37 has I.D. groove in the outside diameter of lugs, as shown in Figure 93, and this sleeve along with the proper valve must go in bore number 37, and the same for bore number 38. 8. The valve can also be installed into the sleeve backwards. It goes into the sleeve small end first, and then the assembly gets installed with the I.D. groove on sleeve facing out. 9. Refer to Figure 93 and 94, and use extra care when installing the valve trains into bore No. 37 and 38. Note: These two valve trains are identical on the VW, Jaguar, and Freelander transaxles. All 3 have the same I.D. grooves as shown.
Copyright © 2008 ATSGCopyright © 2008 ATSG
Copyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
21 LOWER VALVE BODY CASTING 39 REDUCTION REDUCING VALVE TRAIN 40 REDUCTION TIMING VALVE TRAIN 41 LINE PRESSURE RELIEF BALL AND SPRING 42 PRESSURE REGULATOR VALVE TRAIN 43 2-4 CLUTCH ACCUM REGULATOR SWITCH VALVE TRAIN 44 ACCUMULATOR CONTROL VALVE "B" VALVE TRAIN 45 HIGH CLUTCH ACCUMULATOR REGULATOR SWITCH VALVE 46 THROTTLE ACCUMULATOR "B" VALVE TRAIN 47 HIGH CLUTCH ACCUMULATOR PISTON AND SPRING 48 LOW CLUTCH ACCUMULATOR PISTON AND SPRING 49 SHIFT VALVE "C" VALVE TRAIN
23
23
DD
21
39
40
42 41
43
44
45
46
47
48
49
73
LowerValve Body
Figure 96
Copyright © 2008 ATSG
Copyright © 2008 ATSG
COMPLETED SUB LOWER VALVE BODY ASSEMBLY
Figure 95
10. Check the line pressure solenoid for the proper resistance, as shown in Figure 91. 11. Install new "O" rings, lube with ATF and install only the pressure control solenoid, as shown in Figure 90. Torque bolts to 10 N·m (88 in.lb).
FREELANDER VALVE BODY ASSEMBLY (CONT'D)
12. Set completed sub lower valve body assembly aside for final valve body assembly, as shown in Figure 95. 13. Disassemble the lower valve body, as shown in Figure 96, and place the valves, bore plugs and retainers in appropriate trays exactly as they were removed. 14. Clean lower valve body parts thoroughly and dry with compressed air. 15. Assemble lower valve body parts exactly as they are shown in Figure 96, and lube with ATF as they are installed. Note: Install the retainers exactly as shown in Figure 96, as they install in different directions through out the valve body.
23
01
.09.03
DJC
7JP
DD
214124
Continued on Page 74
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
74
Copyright © 2008 ATSG
Copyright © 2008 ATSG
FREELANDER VALVE BODY ASSEMBLY (CONT'D) COMPLETED LOWER VALVE BODY ASSEMBLY 16. Install two new scarf-cut seal rings on both the high and the low clutch accumulator pistons, as shown in Figure 97, and ensure the scarf-cut is configured properly. 17. Lubricate both pistons and seals with a small amount of ATF and install them into the bores, as shown in Figure 96. 18. Install new "O" ring on both the high and the low clutch accumulator covers, as shown in Figure 97, and lube with small amount of ATF. 19. Install both high and low clutch accumulator springs, that were previously labeled, in their proper positions as shown in Figure 96. 20. Install high clutch accumulator cover, using care so as not to damage the "O" ring. 21. Compress the cover and install the snap ring shown in Figure 96. 22. Install low clutch accumulator cover, using care so as not to damage the "O" ring. 23. Compress the cover and install the snap ring shown in Figure 96. 24. Set the completed lower valve body aside for the final valve body assembly process.
High and Low ClutchAccumulator Piston
High and Low ClutchAccumulator Cover
Figure 97
Figure 98
23
23
DD
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
Continued on Page 75
75
Copyright © 2008 ATSG
50
51
52
53
5455
56
57
58
59
25
26
54 PILOT VALVE TRAIN 55 ACCUMULATOR SWITCH VALVE TRAIN 56 NEUTRAL CONTROL VALVE TRAIN 57 REVERSE INHIBIT VALVE TRAIN 58 SHIFT VALVE "B" VALVE TRAIN 59 FAILSAFE VALVE TRAIN
24 INTERNAL VALVE BODY CASTING 25 PLASTIC CHECK BALL (.218" DIAMETER, 5 REQUIRED) 26 STEEL CHECK BALL (.218" DIAMETER, 4 REQUIRED) 50 SHIFT VALVE "A" VALVE TRAIN 51 TCC CONTROL VALVE TRAIN 52 NEUTRAL SHIFT VALVE TRAIN 53 MANUAL SHIFT VALVE
FREELANDER VALVE BODY ASSEMBLY (CONT'D)
25. Disassemble the internal valve body, as shown in Figure 99, and place the valves, bore plugs and retainers in appropriate trays exactly as they were removed from casting. Note: There is no need to remove the bore plug and retainer identified with an "A" in Figure 99, as the valve is removed from opposite side. 26. Clean all internal valve body parts thoroughly and dry with compressed air. 27. Assemble internal valve body parts exactly as they are shown in Figure 99, and lube with ATF as they are installed. Note: Install the retainers exactly as shown in Figure 99, as they install in different directions through out the valve body.
28. Install the manual valve into the internal valve body in the direction shown in Figure 99. 29. Install an appropriate size clevis pin clip into groove in the exposed end of manual valve, as shown in Figure 100. Note: This is a temporary measure that will assist in installing the completed valve body on the unit, as it is a "blind" process. This pin clip must be removed before the oil pan is installed. This will also keep you from losing the manual valve. This clevis pin clip can be found at most auto supply stores or farm supply stores.
Continued on Page 76
Figure 99
24
"A"
InternalValve Body
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
76
FREELANDER VALVE BODY ASSEMBLY (CONT'D)
Copyright © 2008 ATSG
CLEVIS PIN CLIPON MANUAL VALVE
(TEMPORARY)
Figure 100
= Steel Ball .218" Diameter, 4 Required
= Plastic Ball .218" Diameter, 5 Required
Copyright © 2008 ATSG
Figure 101
30. Install the four steel check balls in their proper positions, as shown in Figure 101. 31. Install the five plastic check balls in their proper positions, as shown in Figure 101. 32. Set the completed internal valve body aside for final valve body assembly (See Figure 102). Note: Set aside with the check ball side facing up so as not to lose the check balls.
Copyright © 2008 ATSG
COMPLETED INTERNAL VALVE BODY ASSEMBLY
Figure 102
Continued on Page 77
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
77
33. Install one 67mm bolt and one 90mm valve body bolt through the upper valve body casting as shown in Figure 104. Note: The holes in components that these bolts go through have a very close tolerance and act much like alignment dowels. 34. Lay the assembly on a flat work surface with the worm track side facing up, as shown in Figure 104. 35. Install four plastic check balls in their proper locations, as shown in Figure 103. 36. Install spacer plate "C" with bonded gaskets over the two bolts and onto the upper valve body, as shown in Figure 104, ensuring that you have the proper spacer plate for the Freelander ("Triangle C"). 37. Install the completed internal valve body over the two bolts and onto spacer plate "C", as shown in Figure 104, and ensure check balls are still in position. Note: Do not remove the clevis pin clip from the manual valve at this time.
Copyright © 2008 ATSGCopyright © 2008 ATSG
= Plastic Ball .218" Diameter, 4 Required
4
5
31
30
23
24
28
4 VALVE BODY BOLT, 67MM LENGTH 5 VALVE BODY BOLT, 90MM LENGTH 23 SPACER PLATE "B" (NO GASKETS USED) 24 INTERNAL VALVE BODY CASTING 28 SPACER PLATE "C" WITH BONDED GASKETS 30 PLASTIC CHECK BALL (.218" DIAMETER, 4 REQUIRED) 31 UPPER VALVE BODY CASTING
Figure 103 Figure 104
FREELANDER VALVE BODY ASSEMBLY (CONT'D)
Continued on Page 78
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
78
Copyright © 2007 ATSGCopyright © 2007 ATSG
23
23
DD
23
23
DD
12
15
13
FREELANDER VALVE BODY ASSEMBLY (CONT'D)
38. Install spacer plate "B" over the two bolts, as shown in Figure 104, ensuring that you have the proper spacer plate with the "F" for the Freelander. Note: There are "No" gaskets used with spacer plate "B". 39. Install completed lower valve body assembly over the two bolts, on top of spacer plate "B", as shown in Figure 105. 40. Install the two tapered coil spring loaded filters into their pockets in the lower valve body, with the spring side down, as shown in Figure 106. 41. Install spacer plate "A" with bonded gaskets over one bolt onto the lower valve body, as shown in Figure 106, ensuring you have the proper spacer plate for Freelander ("A" "E"). Note: Ensure that the two spring loaded filters engage into the square holes in spacer plate "A" as it is lowered into place.
Figure 106Figure 105
Completed LowerValve Body Assembly
12 PILOT FILTER WITH "LEAF" SPRING 13 SPACER PLATE "A" WITH GASKETS 15 TAPERED COIL SPRING LOADED FILTERS (2 REQUIRED)
Continued on Page 79
42. Install the pilot filter with the "leaf spring" facing up, and the wide leg of the "leaf spring" facing the bottom of valve body, as shown in Figure 106. Note: This filter must also engage into square hole in spacer plate "A".
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
23
23
23
01
. 09
. 03
DJC
7JP
DD
214124
DD
62
1 VALVE BODY BRACKET 2 VALVE BODY BOLT, 37MM LENGTH 3 NUT FOR VALVE BODY BOLT FROM BOTTOM 5 VALVE BODY BOLT, 90MM LENGTH 6 VALVE BODY BOLT, 24MM LENGTH
23
23
DD
79
Figure 107
Copyright © 2008 ATSGCopyright © 2008 ATSG
23
01
. 09
. 03
DJC
7JP
DD
214124
FREELANDER VALVE BODY ASSEMBLY (CONT'D)
Figure 108
Completed Sub LowerValve Body Assembly
43. Install the completed sub lower valve body over the bolt and on top of spacer plate "A", as shown in Figure 107. Note: Check once again that all three filters are engaged in spacer plate holes. 44. Install the valve body bracket over bolt and on top of the sub lower valve body, as shown in Figure 107. 45. Install 90mm (5) and 37mm (2) bolts through the bracket, as shown in Figure 107, and hand tighten only at this time.
46. Install nut (3) on 90mm bolt coming through from the bottom, as shown in Figure 107, and hand tighten only at this time. 47. Install one 24mm bolt (6), in location shown in Figure 107, and hand tighten only. 48. Install a 37mm bolt (2), from the bottom, in the lower left side of the valve body, as shown in Figure 108, install nut (3), hand tighten only. 49. Install five 37mm bolts (2), in locations shown in Figure 108, and hand tighten only. Note: One of these bolts has a internal wire harness retainer (61). 50. Install one 67mm bolt (4), in location shown Figure 108, and hand tighten only. 51. Install one 90mm bolt (5), along with the wire harness retainer (62), in the location shown in Figure 108, and hand tighten only.1
5
3
3
22
2
2
2
2
4
6
61
5
2 VALVE BODY BOLT, 37MM LENGTH 3 NUT FOR VALVE BODY BOLT FROM BOTTOM 4 VALVE BODY BOLT, 67MM LENGTH 5 VALVE BODY BOLT, 90MM LENGTH 6 VALVE BODY BOLT, 24MM LENGTH 61 INTERNAL SOLENOID WIRE HARNESS CLIP 62 INTERNAL SPEED SENSOR WIRE HARNESS CLIP
Continued on Page 80
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
23
23
23
01
. 09
. 03
DJC
7JP
DD
214124
DD
23
23
23
01
. 09
. 03
DJC
7JP
DD
214124
DD
23
23
23
01
. 09
. 03
DJC
7JP
DD
214124
DD
80
Figure 111Figure 110
4 VALVE BODY BOLT, 67MM LENGTH 5 VALVE BODY BOLT, 90MM LENGTH 60 INTERNAL SOLENOID HARNESS BRACKET
605
5
554
Figure 109
FREELANDER VALVE BODY ASSEMBLY (CONT'D)
52. Install 67mm (4) bolt in the location shown in Figure 109, and hand tighten only. 53. Install four 90mm (5) bolts in locations shown in Figure 109, and hand tighten only. Notice that one has a wire harness bracket (60).
54. Install the eleven valve body to case bolts in their proper holes for alignment purposes. Note: These are the silver bolts. 55. Beginning in the center and working your way outward, torque all installed valve body bolts to 10 N·m (88 in.lb.), as shown in Figure 110. Note: On the two nuts, you may have to hold bolt from the back side with a wrench. 56. Now you can remove the eleven silver valve body to case bolts. 57. Install new "O" ring, lube with ATF and install the low clutch timing solenoid, using one 90mm (5) bolt, as shown in Figure 111. Note: Low Clutch Timing Solenoid should check at 14 to 18 Ohms resistance. 58. Install one silver valve body to case bolt (64), for alignment purposes, as shown in Figure 111 and torque the gold retaining bracket bolt to, 10 N·m (88 in.lb.), and remove the silver valve body to case bolt.
Copyright © 2008 ATSG Copyright © 2008 ATSG
5 VALVE BODY BOLT, 90MM LENGTH 8 LOW CLUTCH TIMING SOLENOID 64 VALVE BODY TO CASE BOLT, 90MM LONG (SILVER IN COLOR)
Continued on Page 81
Low Clutch Timing Solenoid14 to 18 Ohms Resistance
TORQUE INSTALLED BOLTS TO10 N·M (88 IN.LB.)
5
8
64
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
23
23
23
01
. 09
. 03
DJC
7JP
DD
214124
DD
23
23
23
01
. 09
. 03
DJC
7JP
DD
214124
DD
5 VALVE BODY BOLT, 90MM LENGTH 9 2-4 BRAKE TIMING SOLENOID 10 2-4 BRAKE DUTY SOLENOID 64 VALVE BODY TO CASE BOLT, 90MM LONG (SILVER IN COLOR)
Copyright © 2008 ATSG
Figure 112
FREELANDER VALVE BODY ASSEMBLY (CONT'D)
59. Install new "O" ring on 2-4 brake duty solenoid and lube with ATF (See Figure 112). Note: 2-4 Brake Duty Solenoid should check at 2.6 to 3.2 Ohms resistance. 60. Install 2 new "O" rings on the 2-4 brake timing solenoid and lube with ATF (See Figure 112). Note: 2-4 Brake Timing Solenoid should check at 14 to 18 Ohms resistance. 61. Assemble the 2-4 brake duty solenoid onto the 2-4 brake timing solenoid, and install both pieces as an assembly into the valve body, as shown in Figure 112. 62. Install one 90mm gold bolt (5), and one 90mm silver bolt (64) for alignment purposes only, as shown in Figure 112, and torque the gold bolt to 10 N·m (88 in.lb.). 63. Install new "O" rings, lube with small amount of ATF, and install TCC solenoid in the valve body, with 90mm bolt, as shown in Figure 113. Note: TCC Solenoid should check at 12 to 13.2 Ohms resistance. 64. Hand tighten only the 90 mm bolt at this time. Note: The ground wire from line pressure solenoid goes under this bolt.
Copyright © 2008 ATSG
5 VALVE BODY BOLT, 90MM LENGTH 16 TORQUE CONVERTER CLUTCH SOLENOID
Figure 113
TCC Solenoid12 - 13.2 Ohms Resistance
Continued on Page 82
81
64
5
The 2/4 Brake Timing Solenoid and the 2/4 Duty Solenoid are placed together and installed into the valve body at the same time, as shown below.
9
10
16
5
2/4 Brake Duty Solenoid2.6 to 3.2 Ohms Resistance
2-4 Brake Timing Solenoid14 to 18 Ohms Resistance
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
23
23
23
01
. 09
. 03
DJC
7JP
DD
214124
DD
23
23
23
01
. 09
. 03
DJC
7JP
DD
214124
DD
82
FREELANDER VALVE BODY ASSEMBLY (CONT'D)
Continued on Page 83
4
4 VALVE BODY BOLT, 67MM LENGTH 17 SHIFT SOLENOID "A"
Shift Solenoid "A"14 to 18 Ohms Resistance
Shift Solenoid "B"14 to 18 Ohms Resistance
Copyright © 2008 ATSG Copyright © 2008 ATSG
Figure 114 Figure 115
65. Install new "O" ring, lube with ATF, and install shift solenoid "A" into valve body, as shown in Figure 114. Note: Shift Solenoid "A" should check at 14 to 18 Ohms resistance. 66. Install 67mm (4) bolt, and finger tighten only by just a thread or two, as it must come back out to install oil baffle underneath the bolt. 66. Install new "O" ring, lube with ATF, and install reduction timing solenoid into the valve body, using a 90mm bolt, as shown in Figure 115. Note: Reduction Timing Solenoid should check at 14 to 18 Ohms resistance. 67. Hand tighten only, the 90mm bolt at this time.
17
18
5
Ground WireFrom The Pressure
Control Solenoid GoesUnder TCC Solenoid Bolt
Reduction Timing Solenoid14 to 18 Ohms Resistance
4 VALVE BODY BOLT, 67MM LENGTH 5 VALVE BODY BOLT, 90MM LENGTH 18 REDUCTION TIMING SOLENOID 19 SHIFT SOLENOID "B"
4
19
68. Install new "O" rings, lube with small amount of ATF, and install shift solenoid "B" into the valve body, using a 67mm bolt, as shown in Figure 115. Note: Shift Solenoid "B" should check at 14 to 18 Ohms resistance. 69. Hand tighten only the 67mm bolt at this time.
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
23
23
23
01
. 09
. 03
DJC
7JP
DD
214124
DD
23
23
23
01
. 09
. 03
DJC
7JP
DD
214124
DD
23
23
23
01
. 09
. 03
DJC
7JP
DD
214124
DD
74. Set the completed valve body assembly aside, for the final transaxle assembly process. Note: Notice in Figure 118, clevis pin clip is still in place and must remain there until the valve body is installed onto the case, plus you haven't lost the manual valve yet.
70. Install new "O" rings, lube with small amount of ATF, and install shift solenoid "C" into the valve body, as shown in Figure 116. Note: Shift Solenoid "C" should check at 14 to 18 Ohms resistance. 71. Shift solenoid "C" is bolted in the valve body using a nut on the 67mm bolt from the bottom, as shown in Figure 116. 72. Remove previously installed shift solenoid "A" bolt and install oil baffle under the nut and the previously installed bolt (See Figure 116). 73. Now, you can torque the remaining solenoid retaining bolts to 10 N·m (88 in.lb.), as shown in Figure 117.
14
PREVIOUSLY INSTALLED67MM SHIFT SOLENOID "A"
VALVE BODY BOLT
83
Copyright © 2008 ATSG
Figure 116 Figure 118
Figure 117
FREELANDER VALVE BODY ASSEMBLY (CONT'D)
20
3
4
3 NUT FOR VALVE BODY BOLT FROM BOTTOM 4 VALVE BODY BOLT, 67MM LENGTH 14 OIL BAFFLE 20 SHIFT SOLENOID "C"
Shift Solenoid "C"14 to 18 Ohms Resistance
Copyright © 2008 ATSG
NOTICE CLEVIS PIN CLIP IS STILL IN PLACEAND MUST REMAIN THERE FOR NOW
COMPLETED FREELANDERVALVE BODY ASSEMBLY
Copyright © 2008 ATSG
TORQUE REMAINING SOLENOID BOLTSTO 10 N·M (88 IN.LB.)
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
FLUID REQUIREMENTS CHECKING FLUID AND FILLING PROCEDURES
MAZDA "6" AND MAZDA "MPV"
Fluid Requirements Mercon "V"®
Fills Through DipstickTube, Close To
Final Drive
Mazda "6" 9.7 Qts.Mazda "MPV" 10.3 Qts
ApproximateDry Fill Capacity
Transaxle Fills
VOLKSWAGEN
Fluid Requirements G052990A2
Fills Through Fill PlugOn Top Of Side Pan
Golf, Jetta, GTI7.4 Qts
ApproximateDry Fill Capacity
Transaxle Fills
FREELANDER
Fluid Requirements Texaco N402
Fills Through Fill PlugOn Top Of Side Pan
9.1 QtsApproximateDry Fill Capacity
Transaxle Fills
JAGUAR "X" TYPE
Fluid RequirementsIDEMITSUK K-17
(JATCO 3100 PL085)
Fills Through Fill PlugOn Top Of Side Pan
9.3 QtsApproximateDry Fill Capacity
Transaxle Fills
You must use the recommended fluid for each of the individual applications. The friction material, fluid type, engine size, vehicle weight and transaxle fluid operating pressures, are all engineered to be compatable with the electronic calibrations to ensure proper shift feel and durability. The factory recommended fluid requirements are as shown in Figure 119.
Figure 119
Mazda "6" And Mazda "MPV"
Fluid requirements are the same for the Mazda "6" and the Mazda "MPV". Both units are filled through the dipstick tube, located close to the final drive. The fluid should be checked while hot at 60-70°C (149-158°F) and should be at the level on dipstick, as shown in Figure 120. The drain plug is located on the bottom of the converter housing part of the case, just in front of where the two case pieces split.
ATF Type = Mercon "V"® or equivalent
20°C 65°C
HOT RANGEATF TEMPERATURE60-70°C (146-158°F)
COOL RANGEATF TEMPERATURE15-25°C (59-77°F)
Figure 120
Volkswagen, Jaguar, And Freelander
CAUTION: Because of the similarity to other plugs and fasteners on the transaxle case, there is great potential for loosening an incorrect fastener, instead of the fluid level check plug. If the wrong plug is removed, there is a hugh risk of internal transaxle damage. The check plug is the one with the 5mm Allen Head. Refer to Page 87 for the most common mistake when removing plugs.
The Volkswagen, Jaguar, and Freelander have the fluid level check plug installed vertically into the bottom side of the transaxle case, as shown in Figure 121. The fluid level check plug all have a 5mm Allen Head, and closes the lower end of an internal fluid level tube, as shown in Figure 121. Only the excess fluid will be expelled when the check plug is removed. The Jaguar and Freelander check plug is located along side of the selector cable bracket, as shown in Figure 122. The Volkswagen check plug is located about 4 inches behind the pan rail on the bottom of the transaxle case. All three have 5mm allen head, as shown in Figure 122.
Continued on Page 85
Copyright © 2008 ATSG
Copyright © 2008 ATSG
84 AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
Check Pipe
Check Plug
Check Pipe
Fluid Level
Fluid Should "Drip"Out Of Threads Check Plug
Case
VOLKSWAGEN, JAGUAR, AND FREELANDERHAVE CHECK PIPE AND CHECK PLUG
View Looking At BottomSide Of Transaxle Case
Jaguar, FreelanderCheck Plug
CHECKING AND FILLING PROCEDURES (CONT'D)Volkswagen, Jaguar, And Freelander (Cont'd)
1. Vehicle must be parked on a level surface. 2. Remove the fill plug from the top of side cover, as shown in Figure 123. 3. If after rebuild, add 5 quarts of appropriate fluid for the vehicle, as shown in Figure 119 4. Start the engine and allow engine to idle in the "Park" position, and immediately add 3 more quarts of fluid. 5. Shift the vehicle with the manual shift lever through each position, pausing in each position for about 3 seconds. 6. Shift back to the "Park" position and allow the engine to idle to raise the fluid temperature to rise above 40°C (104°F). 7. Remove the "5mm Allen Head" fluid check plug from the bottom of the transaxle case, and allow to drain into a clean container. Caution: Care MUST be exercised when you remove the fluid check plug, as the fluid is very HOT. 8. Allow fluid to drain until it drips intermittently. 9. If no fluid comes out, add the appropriate ATF until it drips intermittently (See Figure 121).10. Install a new washer on the fluid check plug, and tighten to 16.5 N·m (10 ft.lb.).
Figure 122
Figure 121
85
Copyright © 2008 ATSG
Copyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
Yes
No
No
5mm Allen Head
V W A GJP JC7
0 9 A 3 2 1 8 11
Figure 123
FPPM200MAZDA
0212132YO9743
MAZDA
0 STUDS 4 STUDS
2 STUDS3 STUDS
VOLKSWAGEN
FREELANDERJAGUAR
Fills Through Dipstick Tube By Final Drive Fill Plug
Fill Plug
Studs
Fill Plug
Each of the oil pans are also different, as shown in Figure 123. The Volkswagen, Jaguar and Freelander all have studs on the oil pan, in different locations, for various shaped brackets for the individual applications. Notice also that those three have a fill
OIL PAN FILL PLUG LOCATIONSpipe and plug on the top of the pans, and the Volkswagen and Jaguar vent through the pan, where the others do not. The Mazda pan has zero studs and no fill plug on the pan, as it fills through the dipstick tube in the case, near the final drive.
Vent
Vent
Copyright © 2008 ATSG
86 AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
Figure 124
COMPLAINT:
CAUSE:
CORRECTION:
"DO NOT"REMOVE
VOLKSWAGEN, JAGUAR, AND FREELANDERJF506E TRANSAXLE
Volkswagen, Jaguar, and Freelander vehicles equipped with the JF506E transaxle may exhibit a no reverse condition and barely moves forward, after a rebuild, or after a fluid change.
The cause may be, the reduction band anchor bolt was accidently mistaken for a fluid fill plug. When the plug was removed to fill the unit with fluid, the band dropped out of position. Refer to Figure 124.
Some technicians have said they were able to lift the band back into position through the servo bore. If this cannot be achieved, the transaxle must be removed and disassembled to gain access to the band to place it back into proper position.When filling the unit, remove the fluid check plug from the bottom of the case, as shown in Figure 121 and 122, and fill the unit through the fill pipe located on top of the side of the pan, as shown in Figure 123.
NO REVERSE AND SLIPS FORWARD,AFTER REBUILD OR FLUID CHANGE
87
Copyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
}
Low ClutchPressure Tap
Low ClutchPressure Tap
Mazda"Top View"
Volkswagen"Top View"
Special Note:LINE PRESSURE TEST
MAZDA LOW PRESSURE TAP LOCATION
VOLKSWAGEN LOW PRESSURE TAP LOCATION
Wv
JC7JP
NILES JAPAN
>PA66=GF33<
3E09
Line pressure cannot be measured on the JF506E transaxle. Use the "Low Clutch" tap when testing in "D", "4", "3", and "2" range positions. Use the "Reverse Clutch" tap when testing in the "R" range position. Pressure specifications shown on Page 91.
Figure 125
Copyright © 2008 ATSG
88 AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
Jaguar"Top View"
Freelander"Top View"
Low ClutchPressure Tap
JAGUAR LOW PRESSURE TAP LOCATION
Low ClutchPressure Tap
FREELANDER LOW PRESSURE TAP LOCATION
Special Note:LINE PRESSURE TEST
Line pressure cannot be measured on the JF506E transaxle. Use the "Low Clutch" tap when testing in "D", "4", "3", and "2" range positions. Use the "Reverse Clutch" tap when testing in the "R" range position. Pressure specifications shown on Page 91.
Figure 126
89
Copyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
lllll ll ll ll ll ll ll ll ll ll ll ll ll ll ll ll ll ll llll llll ll
High Clutch Pressure Tap
Reduction BandPressure Tap
2-4 ClutchPressure Tap
Reverse ClutchPressure Tap
(All JF506E Models)
Special Note:LINE PRESSURE TEST
Line pressure cannot be measured on the JF506E transaxle. Use the "Low Clutch" tap when testing in "D", "4", "3", and "2" range positions. Use the "Reverse Clutch" tap when testing in the "R" range position. Pressure specifications shown on Page 91.
Figure 127
Copyright © 2008 ATSG
90 AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
MAZDA "6"
RANGE PRESSURE TAP IDLE STALL
"D",
"R",
Low Clutch
Reverse Clutch
42-71 psi
80-109 psi
186-215 psi
225-254 psi{
MAZDA "MPV"
RANGE PRESSURE TAP IDLE STALL
"D", "3",
"2",
"R",
Low Clutch
Low Clutch
Reverse Clutch
42-71 psi
80-109 psi
80-109 psi
186-215 psi
225-254 psi
225-254 psi{
VOLKSWAGEN
RANGE PRESSURE TAP IDLE STALL
"D", "4", "3"
"2",
"R",
Low Clutch
Low Clutch
Reverse Clutch
49-55 psi
73-88 psi
73-88 psi
179-195 psi
220-290 psi
220-290 psi{
JAGUAR X TYPE
RANGE PRESSURE TAP IDLE STALL
"D", "4", "3"
"2",
"R",
Low Clutch
Low Clutch
Reverse Clutch
42-71 psi
80-109 psi
80-109 psi
186-215 psi
225-254 psi
225-254 psi{
FREELANDER
RANGE PRESSURE TAP IDLE STALL
"D", "4",
"2", "1",
"R",
Low Clutch
Low Clutch
Reverse Clutch
42-71 psi
80-109 psi
80-109 psi
186-215 psi
225-254 psi
225-254 psi{
Special Note:LINE PRESSURE TEST
Line pressure cannot be measured on the JF506E transaxle. Use the "Low Clutch" tap when testing in "D", "4", "3", and "2" range positions. Use the "Reverse Clutch" tap when testing in the "R" range position. Pressure specifications have been published only for the Mazda, but all models should check very close to the same pressures, as the calibrations are very close, and those pressures are all shown below by model.
Figure 128
91
Copyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
J P
6
A
J C 7
1 PUMP TO CONVERTER HOUSING "D" RING 2 OIL PUMP HOUSING 3 OUTER GEROTOR 4 INNER GEROTOR 5 OIL PUMP COVER 6 PUMP COVER TO OIL PUMP BOLTS (8 REQUIRED)
6
5
4
3
2
INSTALLED WITH THE"STEP" FACING
THE INNER GEROTOR
1
OIL PUMP ASSEMBLY
OIL PUMP BUSHING INSTALLATION
The Oil Pump Assembly has the Gerotor style pump gears, without a pump cresent, as shown in Figure 130. The converter hub bushing in the oil pump also has a step in it, that gets installed facing the pump gears, as shown in Figure 129. Oil Pump specifications are also shown in Figure 129.
Figure 129 Figure 130
INNER GEAR TO FACE .0008" - .0015"
.0008" - .002"
.004" - .006"
COMPONENT
Oil Pump Specifications
SPECIFICATION
OUTER GEAR TO FACE
OUTER GEAR TO BODY
Copyright © 2008 ATSGCopyright © 2008 ATSG
92 AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
mm14
SERVO PISTONHOLDING TOOL
MAZDA NO. 49 L019 012
14 MM DEEPSOCKET
PLUG AND"O" RING
PISTON ANDSNAP RINGINSTALLED
SERVO PISTONHOLDING TOOL
MAZDA PART NUMBER49 L019 012
REDUCTION BAND ADJUSTMENT
The reduction band adjustment in the factory manuals, backing off adjusting screw 5 turns, does not always produce satisfactory transaxle operation. This adjustment could create a "Chatter" condition in forward or reverse and possibly store gear ratio codes. ATSG recommends adjusting the reduction band using the following procedure.
Reduction Band Adjusting Procedure
1. Install the reduction servo return spring, apply piston with new "O" ring. 2. Compress the reduction servo piston assembly and install retaining snap ring with flat side facing down, as shown in Figure 132. 3. Remove the pressure plug and "O" ring from transaxle case, as shown in Figure 132. 4. Install the factory servo piston holding tool, as shown in Figure 132. Note: This is a mandatory tool to get the adjusting screw locking nut torqued properly. We have provided the Mazda part number, as shown in Figure 131 and 132. 5. Install 14 mm deep socket over the adjusting screw locking nut and loosen the nut. 6. Using a dial caliper measure from the top of the 14 mm deep socket, down to a straight edge placed on machined surface of transaxle case, as shown in Figure 133. 7. Record this measurement as "Dimension A". 8. Fully compress the servo piston and the 14mm socket, using a large screwdriver, as shown in Figure 135. 9. With piston fully compressed, measure again from the top of socket down to straight edge, and record the measurement as "Dimension B". 10. Subtract "Dimension B" from "Dimension A". 11. Turn adjusting screw as necessary to achieve, a minimum of 3.175mm (0.125") to a maximum of 4.75mm (0.187"). 12. Torque the adjusting screw locking nut down to 39-50 N·m (30-35 ft.lb.). Caution: Do not allow the band to become dislodged from the band anchor, as indexing the band back into the proper position will require splitting the case halves.
Figure 131
Figure 132
93
Copyright © 2008 ATSG
Copyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
mm14
43
21
12
34
56
78
91
23
45
67
89
12
34
56
78
91
23
45
67
89
12
34
56
78
91
23
45
67
89
56
10
20
30
40
50
60
70
80
90
15
01
40
13
01
20
11
01
00
0
in
mm
EL
EC
TR
ON
ICD
IGIT
AL
CA
LIP
ER
AU
TO P
OW
ER
-OFF
mm
/in0
00.945IN
Measure For Dimension "B"With Piston Compressed
mm14
43
21
12
34
56
78
91
23
45
67
89
12
34
56
78
91
23
45
67
89
12
34
56
78
91
23
45
67
89
56
10
20
30
40
50
60
70
80
90
15
01
40
13
01
20
11
01
00
0
in
mm
EL
EC
TR
ON
ICD
IGIT
AL
CA
LIP
ER
AU
TO P
OW
ER
-OFF
mm
/in0
00.945IN
Measure For Dimension "A"With Piston Released
STRAIGHTEDGE
STRAIGHTEDGE
Figure 133
Figure 134
Figure 135
REDUCTION SERVO DIFFERENCES
The Reduction Servo internal components are all the same with the exception of the servo cover. The Volkswagen models use a bolt on cover and all the others use a snap ring to retain the servo cover in the case, as shown in Figure 136 and 137. The cut-away view shown in Figure 134 is the snap ring cover version but Volkswagen is set up exactly the same, except for the bolt on cover. When removing servo apply piston, tag the servo apply piston return spring for identification, as it is very similar to one of the accumulators.
Copyright © 2008 ATSGCopyright © 2008 ATSG
Copyright © 2008 ATSG
94 AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
1 REDUCTION SERVO RETAINING BOLTS (3 REQUIRED) 2 REDUCTION SERVO COVER AND "O" RING, (BOLT ON) 3 REDUCTION SERVO COVER GASKET (RIBBED STEEL) 4 REDUCTION SERVO CUSHION SPRING 5 SERVO CUSHION SPRING RETAINER AND "O" RING 6 SERVO CUSHION SPRING RETAINER SNAP RING 7 REDUCTION SERVO PISTON SNAP RING 8 REDUCTION SERVO SPACER 9 REDUCTION SERVO APPLY PISTON ASSEMBLY 10 REDUCTION SERVO RETURN SPRING
1
2
3
6
5
4
10
9
8
7
1 REDUCTION SERVO COVER RETAINING SNAP RING 2 REDUCTION SERVO COVER AND "O" RINGS ASSEMBLY 3 REDUCTION SERVO CUSHION SPRING 4 REDUCTION SERVO CUSHION SPRING RETAINER AND "O" RING 5 CUSHION SPRING RETAINER SNAP RING 6 REDUCTION SERVO PISTON SNAP RING 7 REDUCTION SERVO SPACER 8 REDUCTION SERVO APPLY PISTON ASSEMBLY 9 REDUCTION SERVO RETURN SPRING
5
4
3
2
1
9
8
7
6
MAZDA, JAGUAR, FREELANDER VOLKSWAGEN
J PJ C 7
09A 323 529
Figure 136 Figure 137
95
Copyright © 2008 ATSGCopyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
JF506E TRANSAXLE FILTERS
Mazda, Jaguar, Freelander
Volkswagen GTI, Golf, Jetta
Volkswagen "Sharan"
FLUID FILTER DIFFERENCES
Figure 139
The main fluid filter mounts with two of the oil pump retaining bolts and also goes over a roll pin located in transaxle case, as shown in Figure 138 and Figure 139. Currently there are only three filters in production that cover all applications, as shown in Figure 139. The Volkswagen filters are thinner, slightly longer and have a square oil inlet pipe. The other one is thicker, shorter, has a round oil inlet pipe and fits the Mazda, Jaguar and Freelander models. The transaxle case halves must be split to replace this filter. The oil pump to case gasket is a stamped steel gasket, which would normally be "Ribbed" around all oil passage holes. This gasket however, is "Ribbed" only around the pump suction port, as shown in Figure 138. Make sure this gasket is replaced on any service to the transaxle. There have been many reports of valve buzz after rebuild and this gasket has been identified as part of this concern. This gasket is not serviced by any of the car companys except Mazda, and is available under OEM part number FP01-19-221, as shown in Figure 138.
Hole ForRoll Pin
Hole ForRoll Pin
Hole ForRoll Pin
Figure 138
Copyright © 2008 ATSG
Copyright © 2008 ATSG
96 AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
Fluid FilterMounting Bolts
STEEL OIL PUMP TO CASE GASKETTHAT IS "RIBBED" ONLY AROUND
THE FILTER SUCTION HOLEMAZDA PART NUMBER
FP01-19-221
B
C
M5
2 Y
0 4
INPUT SHAFT AND TRANSFER GEAR
There are currently two different input shafts, one with three sealing rings and one with two sealing rings, as shown in Figure 141. The third sealing ring goes into Transfer Gear "A", located directly behind the oil pump assembly and seals lube oil from escaping, which of course changes the inside diameter of the transfer gear. ATSG feels that this 3rd sealing ring may be an upgrade, as we have seen one shaft that was just not yet machined, as shown in Figure 141. Some transfer gears are bored to accept the third sealing ring, as shown in Figure 140, and some are not. You must measure the inside diameter, as shown in Figure 140, to determine whether it is used with a 2 ring input shaft, or a 3 ring input shaft. The transfer gears also vary in tooth count between the various models, as shown in the chart in Figure 142. Be very careful with the selection process, if replacement parts are necessary.
2 RING INPUT SHAFT, GEAR INSIDE DIAMETER MEASURES 0.975"
3 RING INPUT SHAFT, GEAR INSIDE DIAMETER MEASURES 1.050"
Figure 141
Figure 140
two ring and three ring input shafts
Totally Missing
There, But Not Machined
3 Rings Present
"1st Design"
"2nd Design"
"3rd Design"
Special Note:The three ring input shaft and transfer sprocket is definitely the better design and will make a much more durable transaxle.
97
Copyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
MEASURE THEINSIDE DIAMETER
WITH DIAL CALIPER
NP0 80 89 9P 967®NEUKSM AIT
JF506E PLANETARY, DIFFERENTIAL, TRANSFER GEAR RATIO CHARTLand RoverFreelander
2.5L V6
Land RoverFreelander
Turbo DieselMaxda 63.0L V6
1st Gear 3.801 3.801 3.801 3.8013.801 3.801 3.8013.474
2.131 2.131 2.131 2.1312.131 2.131 2.1311.948
1.364 1.364 1.364 1.3641.364 1.364 1.3641.247
0.935 0.935 0.935 0.9350.935 0.935 0.9350.854
0.685 0.685 0.685 0.6850.685 0.685 0.6850.685
2.970
Codes Unknown
2.970 2.970 2.9702.970 2.970 2.970
Transaxle Code "EEB" = 3.45
Transaxle Code "EYN" = 3.45
Transaxle Code "EEF" = 2.82
3.23
41 Teeth2 Ring ID
41 Teeth2 Ring ID
54 Teeth0 Ring ID
52 Teeth0 Ring ID
52 Teeth0 Ring ID
52 Teeth0 Ring ID
54 Teeth0 Ring ID
47 Teeth1 Ring ID
47 Teeth1 Ring ID
65 Teeth0 Ring ID
67 Teeth0 Ring ID
67 Teeth0 Ring ID
67 Teeth0 Ring ID
65 Teeth0 Ring ID
21 Teeth3 Ring ID
21 Teeth3 Ring ID
23 Teeth3 Ring ID
20 Teeth3 Ring ID
20 Teeth3 Ring ID
22 Teeth2 Ring ID
22 Teeth2 Ring ID
68 Teeth3 Ring ID
68 Teeth3 Ring ID
65 Teeth3 Ring ID
69 Teeth3 Ring ID
69 Teeth3 Ring ID
67 Teeth2 Ring ID
67 Teeth2 Ring ID
3.04 3.23
2.714
3.04
2nd Gear
3rd Gear
4th Gear
5th Gear
Reverse
Differential Ratio
Transfer Gear "A"
Transfer Gear "A"
Transfer Gear "B"
Transfer Gear "B"
DifferentialPinion Gear
DifferentialPinion Gear
DifferentialRing Gear
DifferentialRing Gear
Maxda MPV3.0L V6
JaguarX Type
2.0L/2.5L/3.0L
VWGolf
1.9L Diesel
VWJetta
1.8L/2.8L
VWGTI1.8L
Special Note: The above tooth counts were "Observed" counts, from units that we seen during teardown. Notice also that the rings that are normally used for identification, are the same count on many of the ring gears. Use "ONLY" the tooth count for positive identification, and in the case of Transfer Gear "A", you must also measure the inside diameter of the gear, to determine if it is used for 2 ring input shaft or 3 ring input shaft.
Figure 142
Copyright © 2008 ATSG
98 AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
2.87(2.42)
54 Teeth(58 Teeth)
65 Teeth(65 Teeth)
23 Teeth(26 Teeth)
66 Teeth(63 Teeth)
Mazda Volkswagen
V
W
FreelanderJaguar
Figure 143
FINAL DRIVE IDENTIFICATION The Final Drive assembly can be lifted out, after the converter housing is removed from the case. The differentials, shown in Figure 143, and the pinion gears come in various ratios and all are unique to the individual manufacturer.
Refer to the gear ratio chart in Figure 142, on Page 98, for the differential ratios that have been published. These final drive assemblies obviously will not interchange between the manufacturers.
99
Copyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
Figure 144
SmallChamferPiston Stops
HigherPiston Stops
Shorter
LargerChamfer
"1ST DESIGN""Do Not Use" "Mazda Part Number"
FP03-19-480
"2ND DESIGN"
JF506E TRANSAXLE (ALL MODELS)2-3 FLARE OR SLIPS IN 3RD, 4TH AND 5TH
COMPLAINT:
CAUSE:
CORRECTION:
SERVICE INFORMATION:
Mazda, Volkswagen, Jaguar or Freelander vehicles, equipped with the JF506E transaxle, may exhibit a flare on the 2-3 upshift, and/or slips in 3rd, 4th and 5th gear.
The cause may be, a cracked High Clutch Housing/Reverse Piston (See Figure 144). This crack is extremely difficult to see, and if missed during rebuild will cause premature high clutch failure. When this piston is cracked, it allows high clutch fluid to bleed into the reverse clutch circuit when the unit is in 3rd, 4th and 5th gear. The reverse clutch circuit is open to exhaust, when the unit is in these gears.
Replace the High Clutch Housing/Reverse Piston assembly, as shown in Figure 144. Refer to Figure 145 for an exploded view of the high and reverse clutch housing for the piston location.
High Clutch Piston Housing/Reverse Piston (Mazda Part No.) .................... FP03-19-480Special Note:This piston is only available individually from Mazda, but works just fine in the other units. All others it is not sold seperately.
Copyright © 2008 ATSG
100 AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
101 REVERSE CLUTCH HOUSING ASSEMBLY 102 HIGH CLUTCH HOUSING/REVERSE PISTON ASSEMBLY 103 HIGH CLUTCH PISTON 104 HIGH CLUTCH PISTON RETURN SPRING 105 HIGH CLUTCH BALANCE PISTON 106 HIGH CLUTCH BALANCE PISTON SNAP RING 107 HIGH CLUTCH STEEL PLATES
109 HIGH CLUTCH BACKING PLATE 110 HIGH CLUTCH BACKING PLATE SNAP RING 111 REVERSE CLUTCH STEEL PLATES 112 REVERSE CLUTCH FRICTION PLATES 113 REVERSE CLUTCH BACKING PLATE 114 REVERSE CLUTCH BACKING PLATE SNAP RING
101
102
103
104
105
106
109
110
113
114
111
112
107
108
Figure 145
101
Copyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
102 AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
NP0 80 89 9P 967®NEUKSM AIT
LubeGasket
LUBE GASKET LOCATION
VOLKSWAGEN JF506EREPEATED LUBE FAILURE
COMPLAINT:
CAUSE:
Repeated planetary failure, from lack of lubrication, on any Volkswagen equipped with the JF506E transaxle. Has normally been occurring after rebuild.
The cause may be, not installing the "beaded" gasket between the case and the converter housing, or installing the wrong "beaded" gasket, as shown in Figure 146. Jatco changed this gasket during the 2003 model year because of a change in the case pocket depth. This gasket is in the Volkswagen aftermarket kits only, as Volkswagen is the only manufacturer that uses the cooler mounted externally on the transaxle case, as shown in Figure 148. There are tubes that run from the back side of the converter housing, internally over to the cooler.
CORRECTION: Now there will be two different thickness gaskets included in your kits, and this will require you to measure the thickness of the original gasket metal core, before discarding, as shown in Figure 147. The 1st design gasket (1999-Some 2003) has a metal core thickness of .203mm (.008"). The 2nd design gasket (Some 2003-Up) has a metal core thickness of .610mm (.024"). Install the correct "beaded" gasket between the case and the converter housing, as shown in Figure 146.
Figure 146
Copyright © 2008 ATSG
103AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
43211 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
5 6
10 20 30 40 50 60 70 80 90 1501401301201101000
in
mm
ELECTRONICDIGITAL CALIPERAUTO POWER-OFF
mm/in 0
00.024IN
VolkswagenGolf, GTI And Jetta
Cooler Mounted ExternallyOn Transaxle
Figure 148
Figure 147
Copyright © 2008 ATSG
Copyright © 2008 ATSG
1999 Models Through Some 2003 = .203mm (.008") Thickness
Some 2003 Through Current Models = .610mm (.024") Thickness
measuring gasket metal core thickness
DIRECT CLUTCH HOUSING
3.80 1ST GEAR RATIO MODELS 3.47 1ST GEAR RATIO MODELS
DIRECT CLUTCH DIFFERENCESDirect Clutch Housing Reduction Planetary Carrier
23 ToothReductionSun Gear
23 ToothDirect Clutch
Housing
Selective For23 ToothSun Gear
Selective For31 ToothSun Gear
Large Diameter24.78mm (.975")
BearingIs The Same
BearingIs The Same
Small Diameter23.50mm (.925")
31 ToothDirect Clutch
Housing
31 ToothReductionSun Gear
The Direct Clutch Housing is different, depending on the planetary gear ratio of your unit, because the reduction sun gear "splines" into the direct clutch housing, as shown in Figure 149. The Freelander uses a 23 Tooth sun gear, while all others use a 31 Tooth sun gear, as shown in Figure 149. Since the reduction sun gear is a different diameter, it also changes the "hub" of the selective thrust bearing race, as shown in Figure 149. The thrust bearing assembly for this area is the same on all models. The direct clutch stack-up is also different between the 4 clutch and the 3 clutch direct clutch housings. Refer to Page 106.
The Reduction Planetary Carrier is going to have different size pinion gears in the carrier obviously because of the ratio difference. The pilot that goes into the direct clutch housing has a diameter on it that is compatable with the 23 Tooth sun gear, as shown in Figure 150, only on the area down between the pinion gears where the sun gear rotates. The reduction sprag parts are the same on all models, also shown in Figure 150.
Figure 149
Copyright © 2008 ATSG
104 AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
NP0
80
89
9P
967®NE
UK
SM
A
IT
NP0
80
89
9P
967®NE
UK
SM
A
IT
Diameter DifferenceDown Between ThePinions Where Sun
Gear Rotates
Diameter DifferenceDown Between ThePinions Where Sun
Gear Rotates
Larger PinionsBecause Of Ratio
Difference
Smaller PinionsBecause Of Ratio
Difference
3.80 1ST GEAR RATIO MODELS 3.47 1ST GEAR RATIO MODELS
Figure 150
} }Same OnAll Models
Same OnAll Models
105
Copyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
4 Clutch ID2 "Divots"
3 Clutch IDNone
DIRECT CLUTCH STACK-UP
MAZDA, VOLKSWAGEN, JAGUAR FREELANDER
31 Tooth Sun Gear4 Clutch Direct Drum
Stack-Up
23 Tooth Sun Gear3 Clutch Direct Drum
Stack-Up
6.83mm (.269")8.33mm (.329")
3.80 1ST GEAR RATIO MODELS 3.47 1ST GEAR RATIO MODELS
DIRECT CLUTCH DIFFERENCES (CONT'D)Direct Clutch Stack-Up Direct Clutch Piston
The direct clutch friction and steel plates also stack differently, as shown in Figure 151. There is a 4 friction and 4 steel stack, and a 3 friction and 5 steel stack, as shown in Figure 151. The direct clutch backing plate is the same on all models.
The direct clutch apply piston also changes in height, in the area shown in Figure 151, to accommodate the different clutch stack-ups. Be very careful in choosing replacement parts for this area.
Figure 151
Copyright © 2008 ATSG
106 AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
107
Copyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
Low/Reverse Clutch
High Clutch
Reverse Clutch
Low Clutch
Reduction Band
DirectClutch
2-4Clutch
CASE PASSAGE IDENTIFICATION
CASE PASSAGE IDENTIFICATION
Figure 152
Figure 152 identifies the case passages under the valve body for possible air checks, or for removing a particular component. Also shown are the location of the two seals between the valve body and the case.
30
20
31
32
20 TRANSAXLE END COVER 30 2-4 BRAKE CLUTCH PISTON OUTER SEAL 31 2-4 BRAKE CLUTCH PISTON 32 2-4 BRAKE CLUTCH PISTON INNER SEAL
END COVER AND 2-4 CLUTCH PISTON DIFFERENCES
Dimension "A"
Figure 153 Figure 154
2-4 Brake Clutch Piston/End Cover2-4 Brake Clutch Piston/End Cover (Cont'd)
Currently we have confirmed it only in the Volkswagen Sharan, but we have suspicion that it may be in other models as well. It is not known whether it is strictly model differences or a model year change, but we do know that it is out there. Obviously this would also affect the inside diameter of the piston area in the end cover, also shown in Figure 154. The smaller inside diameter piston would create a larger surface area for the 2-4 clutch apply fluid to work with. The smaller inside diameter piston cannot be installed in the cover for the larger diameter piston You can go the other way very easily, but you will not like the result. Ensure that you use extra care if replacement parts are needed for this area.
There are currently two different 2-4 Brake Clutch Pistons, that are different only on the inside diameter, as shown in Figure 154. You will need a dial caliper capable of measuring 6 plus inches.
Copyright © 2008 ATSG Copyright © 2008 ATSG
108 AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
Dimension "B"
PISTON DIMENSIONSDimension "A" Is 161.7mm (6.366") = Smaller Diameter
Dimension "A" Is 164.2 (6.465") = Larger Diameter
END COVER DIMENSIONSDimension "B" Is 161.2mm (6.346") = Smaller Diameter
Dimension "B" Is 163.7 (6.445") = Larger Diameter
20
29
21
22
23
2425
26
27
28
20 TRANSAXLE REAR COVER 21 2-4 BRAKE ACCUMMULATOR PISTON 22 2-4 BRAKE ACCUMMULATOR PISTON SEALS (2 REQUIRED) 23 2-4 BRAKE ACCUMMULATOR PISTON RETURN SPRING 24 2-4 BRAKE ACCUMMULATOR COVER 25 2-4 BRAKE ACCUMMULATOR COVER "O" RING SEAL
26 2-4 BRAKE ACCUMMULATOR COVER SNAP RING 27 REAR END COVER SCARF-CUT SEALING RINGS (3 REQUIRED) 28 REAR COVER TO REAR BEARING "SELECTIVE" THRUST WASHER 29 REAR COVER TO REVERSE CLUTCH HOUSING THRUST BEARING
TRANSAXLE REAR COVER EXPLODED VIEW
REAR COVER "V"-CUT SEALING RINGS
High And Reverse ClutchSeal Rings Are Directional And "Must" Be Installed
As Shown Here
"Arrow" To Right"V"-Cut To Left
Fluid is fed through the rear cover to apply the high clutch and the reverse clutch, which are both located in the reverse clutch housing. The sealing rings for the high and reverse clutch are Teflon® and one end has a point like an "arrow", and the other end is cut out the inverse of an arrow, or like a "V", as shown in Figure 155. These sealing rings are directional, and when installed correctly, the point of the "arrow" is to the right and the "V" is to the left as shown in Figure 155.
Figure 155
109
Copyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
3
230
231
Copyright © 2008 ATSG
110 AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
Narrow Lug
Snap Ring InstallsWith Opening Located
As Shown Here
Narrow Groove
230 LOW ROLLER CLUTCH ASSEMBLY 231 LOW ROLLER CLUTCH SNAP RING
LOW ROLLER CLUTCH AND SNAP RING LOW/REVERSE CLUTCH PACKInstallation Installation
The low roller clutch assembly (230) cannot be installed incorrectly, as the outer case lug configuration will allow for only one possibility. A quick method for installation is to first face the ledge side of the roller clutch housing down towards the case, and align the narrow lug of the housing to the narrow case groove as shown in Figure 156. The retaining low roller clutch snap ring (231) fits properly into the case as shown in Figure 156.
L/R Piston Retainer TabKeys Into This Slot
The low/reverse clutch stepped backing plate (246) fits into the case with the step facing down and lugs into the case in the same fashion as the low roller clutch assembly, as well as the steel plates (248), as shown in Figure 157.The low/reverse piston retainer's (256) outer tab must key into the case as shown in the lower right corner, as shown in Figure 156, so as to properly align the feed hole to the valve body side of the case.
Figure 156
111
Copyright © 2008 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
246
246
INSTALL WITH STEPFACING DOWN
249250251252
253254255256
LOCATING TAB
257
247
248
246 LOW/REVERSE CLUTCH BACKING PLATE 247 LOW/REVERSE FRICTION PLATES 248 LOW/REVERSE STEEL PLATES 249 LOW/REVERSE "SELECTIVE" PRESSURE PLATE 250 LOW.REVERSE "CONE" CUSHION PLATE 251 LOW/REVERSE PISTON RETURN SPRING SEAT 252 LOW/REVERSE PISTON RETURN SPRING
253 LOW/REVERSE APPLY PISTON OUTER "D" RING SEAL 254 LOW/REVERSE CLUTCH APPLY PISTON 255 LOW/REVERSE APPLY PISTON INNER "D" RING SEAL 256 LOW/REVERSE CLUTCH PISTON RETAINER 257 LOW/REVERSE PISTON RETAINER SNAP RING
31
26
00
45
PW
1M
PJ
7
CJ
LOW/REVERSE CLUTCH EXPLODED VIEW
Rear View
Figure 157
112 AUTOMATIC TRANSMISSION SERVICE GROUP
Update Handbook
Figure 158
Figure 159
3
598
597
596
595
595 BOLT WITH "O" RING, 17MM HEAD (2 REQUIRED HERE) 596 BOLT WITHOUT "O" RING, 13MM HEAD (1 REQUIRED) 597 DIRECT CLUTCH HOUSING SUPPORT 598 DIRECT CLUTCH SUPPORT "STEPPED" SEALING RINGS (2)
222
TRANSFER GEAR "A" PARTS EXPLODED VIEW
LOW CLUTCH "STEPPED" SEAL RINGS
DIRECT CLUTCH "STEPPED" SEAL RINGS
221
223
224
225227228229
227
226
221 TRANSFER GEAR "A" (OUTPUT) 222 TAPERED ROLLER BEARING CONE RETAINING SNAP RING 223 TAPERED ROLLER BEARING CONE (DOUBLE) 224 LOW CLUTCH HOUSING SUPPORT 225 CLUTCH SUPPORT TO RING GEAR THRUST BEARING (NO. 2)
226 LOW CLUTCH "STEPPED" SEA;ING RINGS 227 TAPERED ROLLER BEARINGS (2 REQUIRED) 228 LOCKING WASHER WITH TABS
The low clutch support and feed for the low clutch uses a "stepped" sealing ring with a unique step configuration, as shown in Figure 158.
The direct clutch support and feed for the direct clutch also uses the "stepped" sealing rings with the unique step configuration, except they are a different size, as shown in Figure 159.
Phoenix RemanufacturedTransmissions
PHXRETRANS
A VERY HEARTY "THANK YOU" TO FRANK KUPERMANOF PHOENIX REMENUFACTURED TRANSMISSIONS
FOR SUPPLYING US WITH THE TRANSMISSIONS THATMADE THE ILLUSTRATIONS IN THIS BOOKLET POSSIBLE.
www.phoenixhardparts.com